So much for starting on the tailgate. After I got it off, I noticed the driver side inner supports and panel were rotted worse than expected. I welded in a bunch of 16 gauge to reinforce things, then welded 20 gauge to the outer panel to cover it up. The passenger side only needed work on the outer panel.


Inner repair

Not shooting for perfection. Nobody but me will notice here.

So much easier on this side

This time consuming part of fitting pieces

The quickest part.

Close enough for who it's for and where it's located.

 

Once I slowed down my gun speed, the epoxy primer even had a shine. I've never welded (brazed before) or used a spray gun myself before this project, so I shouldn't be hard on myself if not perfect. Tailgate is the only welding and rust repair left that I'm aware of at this point, but it has a leaky windshield that has to come out. I'll probably rework the wheel wells at some point. That was where I started trying to figure out how to weld and looks terrible.

 

Looking good!

 

I sure opened up a mess here. Michigan salted roads suck.

 

I patched the corners, and a small piece on the bottom. When I tried to fit the new panel, it was apparent that the inner panel was bowed downward towards the center. I'm going to try to correct it with some 1/2" square stock. I friend suggested panel adhesive and a flange tool to attach the skin. I was all ready to go that route, but this bowing and the stress a tailgate takes has me thinking I should flange and weld the top seam and panel adhesive with a few spot welds for the sides and bottom?

 

I know it's not pretty, but it'll never be seen and will hold the new skin.

 

Now I find out the replacement piece is 3/4" too long. My brother has a finger brake, so I think I can re-work the piece there. Frustrating, one thing after another.

 

I was getting ready to install the piece, and noticed there was no cutout for the window to operate. Now I have to cut it out where marked, then weld a flange to reinforce it and to hold the weatherstrip.

 

I was going to give up and order a fiberglass piece from toyotafiberglass for $200, but the shipping was going to be $400 plus $200 for the part. If i knew starting out what I know now, i probably would have done the whole thing in fiberglass. There still would have been lots of welding to repair the inner panels to fit the fiberglass.

 

You are doing a great job with your welding skills, you are almost there.
Happy 2023!

 

Thanks for the encouragement. Now that I have it cut out, I think it's going to work. This tailgate sure is time consuming. I knew it would take awhile, but the time is adding up on the tailgate. On the bright side, the only rust repair after this is under the windshield and sunroof.

 

It looks like I'm going to be able to make it work. I got the piece cut out out so the window can open and welded a flange for reinforcement and for the outer weatherstrip to attach. This tailgate sure is time consuming.

 

Work got in the way of the 4runner project, but getting really close on the tailgate. I broke down and bought a 30" Durablock sanding block, and that is helpful on the tailgate, and will be when I smooth the panels out some more.

 

I am going to have to address my tailgate soon, so this thread will be very helpful. I have not even opened it yet because I haven't tried the rear window - which I assume must be down to open it - I just know it has a small hole on the top which I assume lead to the separated seam across the bottom. Did you consider a used tailgate? Great work by the way!

 

Is that tailgate top repair piece from wolf steel?

 

I couldn't find a used tailgate within 600 miles of me. I would have willingly paid dearly for one if I could've found one.

 

Yes it was. It took quite a bit of time to fit. If you noticed above, it didn't have the window opening cutout. They were helpful and great to deal with at Wolf Steel, but if I was starting over, I'd go the fiberglass route. When I found out I needed to cutout the window opening, I did call Toyota Fiberglass about the tailgate skin. $200 wasn't bad, but it was going to be around $400 to ship it. It wouldn't have been much more to ship all the panels. Still a lot of work to do, but I think I'm about done with the rust repair part of it.

 

I found another tailgate about 2 hours off but it was even more rusted than what I had. I knew it was real bad. It was only 20 bucks so I figured just for the rear glass and motor / regulator it was worth getting. It had a lot of good hardware that came in handy but the pieces I needed to fix the rust on mine were just as bad. I had no idea how heavy these were!

 

I know what you mean…I was looking for a spare tailgate just to have. Got a decent one yesterday included with my new project truck. 👍🏻

 

Saweeeeet!


I sent you an email about it.