OEM Drop down tailgate- need template

[spotcruiser]

Nice job, Kief.

I plan to do the same thing with a set of swing-out doors that I have and I plan to add a square tube frame inside the tailgate to strengthen it lengthwise. Did you add anything to yours?

Graham at Immortal4x4 in BC is going to start importing tops and such from Ehsan, so hinges should be available from him in the future (better allow at least six months for this to begin). He is trying to determine a price for me right now. I'll let you know what he comes up with, if you're interested.

 

[Kief]

Thanks, it will look a lot better smoothed out. I was going to reinforce it but with the hinge reinforcements there was interference with the 1/2x1/2 square tubing I was going to put in(concealed) and I didn't want to put it in the inside panel as I wanted to make sure the front was flat and that the back piece conformed to it. It is very strong as it is and the spare tire carrier is just as likely to bend it in as jumping on it would make it sag. A fixed 3/4x3/16 piece of flat steel along the bottom for the hinge bolts would have been less work and stronger. Too much structure would make it hard to repair if something does happen.
I think just marrying two swing out doors together would be a better use of time... I won't say how much time went into this as I am just a neophyte to the fab/welding world and learned quite a bit..
I think the hinges are so simple that a local shop could probably build them for a fair price. I am going to talk a friend who works at a fab shop and see what he thinks. I may mess around with this myself too.

 

[RumBum]

Can someone give me a width measurement of an early model tailgate? I have an '82 I would like to have a drop down for. From what I understand the only issues will be the bold pattern on the tub... but I thought the width at the back of the tub was different for earlier models.

 

[peterb]

Kief
Thanks for the package! You didn't need to but I'm glad you did. Good luck with the project.
Peter

 

[Kief]

my pleasure..

Kief
Thanks for the package! You didn't need to but I'm glad you did. Good luck with the project.
Peter

No prob. Sandblasted the TG and it looks even better. Started playing with my DA and realize I need to get a better compressor....

Anybody got a spare hinge or 3?

 

[Larr75fj40]

Wow, now I want one!. I knew I should of stayed off this site this morning. I'll be thinking about this all day at work.

 

[Kief]

Getting closer to having this thing done... slow going. Anyone have a loaner hinge? I want to try to make 3.. Thanks.

 

[Kief]

update

Well, here is a shot of it in primer, not sure if it is getting painted soon. Working on my '75 and not sure if i will put it on there or not.

 

[tucker74]

Well, here is a shot of it in primer, not sure if it is getting painted soon. Working on my '75 and not sure if i will put it on there or not.

You ever find any hinges? I've got one in my garage needing a set as well

Tucker

 

[Coolerman]

Well, here is a shot of it in primer, not sure if it is getting painted soon. Working on my '75 and not sure if i will put it on there or not.

That looks great!

 

[Kief]

Not yet

You ever find any hinges? I've got one in my garage needing a set as well

Tucker

Looks like gold and drop down tailgate hinges are worth more to hoard so no hinges for me. I'm hopin' to make some after I get my 40 parts painted, so get in touch with me in a few years if you're still lookin'...

 

[spotcruiser]

Finally finished building my drop-down tailgate out of two rusted out half-doors. Installed a 1/2" x 1" figure-8-shaped tubing frame inside the sheet metal to make the whole thing square, flat, and solid. Built hinges out of 3/4" x 3/8" steel tubing and 3/16" flatbar. Built the stationary latches out of angle, similar to robj.

Also extended the tire carrier 3-1/2" inboard to stop the tire from getting hooked on trees that I slide past on the driver's side. Integrated the latch mechanism into the center tailgate hinge.

 

[spotcruiser]

Few more.

 

[Coolerman]

Wow! That looks almost 100% factory! Excellent work...

 

[spotcruiser]

Wow! That looks almost 100% factory! Excellent work...

Thanks Mark. I put a lot of time into them, but most of it was really spent patching the rusted-out areas and straightening dents. If I had purchased better doors to begin with, they would not have required so much effort. Getting the hinge offset correct was a lot of work, but building a set once I had the design figured out was not too difficult.

 

[Kief]

Nice job, I think the internal frame is a good idea. The tubing for the hinges is probably the quickest way to do them if you don't have a thoroughly equipped shop.. Rock on!

It takes a lot of time doesn't it?!

 

[spotcruiser]

Nice job, I think the internal frame is a good idea. The tubing for the hinges is probably the quickest way to do them if you don't have a thoroughly equipped shop.. Rock on!

It takes a lot of time doesn't it?!

Thanks Kief. Yeah, it takes a lot of time. The 3/4"OD x 3/8"ID tubing worked really well. I started out trying to use solid 3/4"OD round stock, but getting everything drilled out in-line is really difficult. Not a problem with the tubing at all.

The frame made everything square and solid and I also welded mounting pads for the hinges, chain mounts, and clamps into it. In addition to being re-welded at the OEM spotwelds, which I drilled out to separate the insides from the outsides to begin with, the indside and outside panels are also spotwelded to the internal frame every few inches. The tailgate is bombproof.