Tailgate Repair

Proof that it can be done by anyone with some rudimentary body-working skills.

First a few "before" photos:

I started grinding on bottom of tailgate,  searching for the end of the hinge pin.   Once I found the pin,  I ground a line down the length of pin.   This effectively removed the factory spot weld, and loosened the "tube"s grip on the pin.   After cutting above the tube full length,  it could be removed.    The sabre saw cut is visible in photo.   I elected to cut the tube out first,  then make another full length cut later (shown below) after marking.

Mike's instructions are to completely remove one of the pins,  but I elected to leave them in place.  It is possible to slide the repair section onto one of the pins (with a some hammer persuasion),  line up the other end,  then "center" the section.   With the section in position,  I marked the tailgate for final cut.   The photo below shows the section coming back off, to allow for the cut to be made.

Ready for final cut:

I got rained out,   so more photos to follow.   I will take some tomorrow of the welding etc.   I thought I would start this thread while it was raining. 

 

Showing the tack welds:

 

 

 

 

Finished . . .  The tailgate looks a little rough, because I was trying to keep a older look to match rest of Jeep,   but the repair looks like new.   The weakness,  bowing,  and rust holes are gone.

 

 

Overall,  I am very happy with the repair section.

 

At the time I got this,  the best way to order was to send PM to "mike in oregon"

 

These will be there to see in person.   Mike's sections make it relatively easy, with a grinder and welder.

 

hmmm . . I can't seem to upload photos   . .  maybe I will try later.

 

Will try using PhotoBucket for now: