My tailgate handle repair

[Dogdoc90]

My tailgate handle broke (as expected) during my restoration and I wanted to share my repair (and failures) along the way. After realizing it couldn’t be welded, I had a local guy tack weld it in position so I could apply a brace using a Simpson truss support. I bent the support into position so it would tightly fit inside the handle then JB welded it into place.

 

[Dogdoc90]

Unfortunately the JB weld failed where it attached to the long arm and separated within a week. After reading about the 3D printed handles, I have one a try. The first one broke at the bolt holes when I tried to drill it out to better fit the bolt. The manufacturer was awesome and immediately reprinted one but it also quickly failed.

 

[Dogdoc90]

The 3D guy was great and refunded my money. Said other Pig owners have had good luck but despite me lubricating the heck out of the latch mechanism, it was too much to ask of carbon fiber. He says he’s going to get a metal printer and try that instead. My final solution was to re epoxy the Simpson plate to the arm and bolt it in place. I drilled 4mm holes through the arm and latch plate, tapped them then screwed them in place. Had to grind the heads way down to make it clear but so far it’s holding. The latch sticks up a bit on the outside but not too noticeable. Hope it keeps working

 

[scrapdaddy]

Man, that was a lot of disappointment. Can I ask what material was used for the 3D printed one?

 

[Dogdoc90]

Man, that was a lot of disappointment. Can I ask what material was used for the 3D printed one?

Carbon fiber. I’m interested in a possible printed metal handle but worry it may be no better than the original cast version and would break at the usual stress point

 

[bobm]

Me too

 

[RUSH55]

Still thinking we should be able to have some cast at a foundry, either out of aluminum or iron or even bronze with the intention of just painting or powder coating.

 

[bobm]

Mmmm, cast is why it breaks. Solid Stainless, in process

 

[Dogdoc90]

Mmmm, cast is why it breaks. Solid Stainless, in process

I would be interested in that!

 

[J Mack]

I would be interested in that!

Grab a chunk of 10 gauge stainless steel and form the handle and have your buddy with the welder weld some ears to it.

 

[bobm]

Blame Henry Ford for inventing Pot metal

 

[Dogdoc90]

Grab a chunk of 10 gauge stainless steel and form the handle and have your buddy with the welder weld some ears to it.

 

[J Mack]

This will give you an idea of how to form metal parts with a buck.

Sheet metal wood buck thread.

how did you get it to roll up with out creases or relief cuts please e-mail me at impala_ss_64_1999@yahoo.com Here is one of the many forms I made to...

www.jalopyjournal.com

I believe a guy could make a hardwood buck and press a handle or two in an H-frame press.

 

[bobm]

Be tough with 304. You'll gain some and need 1 of these