More rear Tailgate questions

[Ry24000]

Hello everyone. I have a question for you. I have been busy knocking down all the little gremlins trying to get everything up and running. My tailgate has the two most common issues. broken handle and broken gear. I have another gear on the way. My handle I may try to weld the crack or fabricate the part cut off the old and weld the new on. Has anyone tried to weld the stainless steel handle's on these pigs?

This crack was wider than you see here. I set the handle in a vice and moved it to close it up some. I can close it up until you can't really even see it at which point I think I could hit it with my TIG and add a tack. I want to pattern the part and make one from a piece of SS steel and possibly weld it on.!?

When I was trying to open the tailgate to no avail I had to open the TG access cover I noticed that something was missing from the window mechanism. A look at the FSM and it appears the piece connecting the Lock Off Lever and a spring. When I bought the vehicle there was some "junk" in the glovebox that included a spring. I think is supposed to be in the gate mechanism?

This is The spring I found in the glove box. I think it's the one?
I think I'll attach the Lock Off Lever with a piece of sturdy wire. Anyone have a picture of the stock setup? I would like to mimic that one. Thanks

 

[Ol Yeller]

I’m fortunate enough to have not fought these items so no help other than to say the handle is pot cast shyt that I doubt you can weld…good luck though and maybe we all learn something.

 

[bobm]

Pot metal can't weld it.

 

[Ry24000]

Ahhh....Pot metal I have heard that term to describe metals before. I thought it was Stainless steel. I looked up pot metal repair and yes it can be done. Ill look into it!
What about the spring and the connecting rod for the Lock Off Lever. Anyone know if the spring in my picture is the one in question? I am 99% sure it is. Any Pictures out there of the Lock off Lever connection?

 

[WarDamnEagle]

That looks like the correct spring. I'll search for a photo and edit this post with what I find.

 

[WarDamnEagle]

Okay, so how about a new post instead.

 

[PabloCruise]

Have we seen your Pig in here?
We like pictures...

As others have said, that handle is not stainless.
@DoubleNickels and I have been through the handle at a detailed level. I checked on having some produced, including machined out of stainless and it looked like every option was going to be $$$. 3D prints seemed like the best option. If you want to machine one, I am happy to share my design files.
I have lots of pics of the tailgate mechanism in my build thread (linked below). I am in the process of trying to index/add tags to that thread, so you will have to hunt. I think you will find tailgate details in the first 10 pages or so.

 

[PabloCruise]

If you haven't been through this thread, it is very useful: Rear window article available from Gary S - https://forum.ih8mud.com/threads/rear-window-article-available-from-gary-s.323706/

 

[Ry24000]

Have we seen your Pig in here?
We like pictures...

I never did an introduction. Ill be sure to post some!

 

[RUSH55]

Why?

 

[Ry24000]

I have to learn how to draw on the pictures like you Rush! Thats the spring alright I need the wire and the clip that the spring is attached to. Ill make something I guess.

 

[RUSH55]

I have to learn how to draw on the pictures like you Rush!

You have an iPhone?

 

[Ry24000]

Android

 

[WarDamnEagle]

Why?

View attachment 3222682

I assume you are asking about the routing of the motor wiring? That's the way I found it. Those were my, "make sure you know how to reassemble this spring and rod before you take everything apart photos". I didn't leave it that way after replacing the motor and gear.

 

[YukonCruisers]

Re the cracked handle, mine was the same and I ended up shaping a piece of metal and sistering it to the lever arm. To do it again I would 3m epoxied it with the screws.

 

[scrapdaddy]

Nice fix!

 

[DoubleNickels]

Right! Look at me, chiming in VERY late as usual.

To Bob's point, the pot metal seems tricky (read: darn-near impossible) to weld, though I've also seen someone TIG up a sheared beer can then drink beer out of it again... i.e. just because I can't do it doesn't mean you can't.

As Pablo mentioned he and I threw a bit of work at a repro handle option. Pablo came to me with the files and I helped print a prototype to verify form/fit. They came out VERY nice.

About that time another gent popped up here on MUD with a link to the very same thing, a 3D printed part he was 'hosting' through Shapeways. I can't seem to find that link, but I see that some are criticizing the appearance of the final product - too much slop and tolerance between moving parts. I'll see if I can find that link.

Based on my history with Pablo's part I do think the fit and tolerance may be better than the other gent's, but I'd need them both in-hand to verify.

Calvin