Bottom Tailgate...

I was able to find a used tailgate which needed a bit of work to it instead of purchasing one for what seems to be an astronomical amount (good clean used parts for these are rare and not cheap!).  So, this one is solid except for the bottom 3" so I snapped it up and got to work on it today.

It's been crazy busy the past few weeks so I've neglected this project.  I hope to pick up the pace again now that things have quieted down a bit.

Last week I did have a chance to stop in at Millstone Sheet Metal in Duncan as they folded a piece of 18awg for my lower rear gate bottom. It was pretty rotten along the bottom. Although 18awg is a little thick, I figured it was worth a try. The one thing that's a bit of an issue is where the brackets are double thick so folding the front edge over to meet the existing edge is a bit tight. This afternoon I got around to cutting out the old and spot welding in the new. 

Dimensions I had them build the new piece was 3"x1"

The new piece is slightly larger on the back side where the 1" goes. I cut it slightly smaller so that I could fold it over and I think it will work out well. Obviously I'll have to add a bunch of seam sealer to that edge, but I think (hope?) it will bolster the strength a bit.

Also, the bottom of the gate has a natural curve to it so I think I was able to match that, but it may also have a bit of a natural rise which I'm not sure I was able to do. I guess I'll see if that matters once I reinstall it!

I'm really wanting to do the Wagongear mod on the tailgate for storage (http://wagongear.com/shop/tailgate-lids/), as well as the rear cargo panels (http://wagongear.com/shop/side-panels/), but unless I can make it happen by personal fabrication it just simply isn't in the budget! I suppose I'm on the lookout for some 1/4" black plastic panelling and some access boxes...

Here's the progress from this afternoon...