D.I.Y. Tailgate.....in 99 easy steps!!!
Roast em' if you got 'em
Joined: Mar 2005
Posts: 21,955
Likes: 9,727
From: Rio Rancho, NM
LOL...yea, I used parts of a toilet seat hinge to hold the tailgate straps...I had forgot about those...LOL
Fordman75, have you looked at modifying a later model tailgate? I had thought about using the center section from a mid 80's stepside for awhile but then I decided I wanted to keep the Ford script center piece in mine.
Bobby
Fordman75, have you looked at modifying a later model tailgate? I had thought about using the center section from a mid 80's stepside for awhile but then I decided I wanted to keep the Ford script center piece in mine.
Bobby
Thread Starter
|
Welder User
Joined: Feb 2009
Posts: 5,269
Likes: 50
From: northwest MT
Part 3
Just want to say thanks for your kind words and comments...keep them coming!
Welding.......
A large flat panel like this is kinda tricky to weld....get it too hot and it will warp like a pretzel. Small welds, and move around alot. I even cool my welds with compressed air....well I did all that and it still warped a little...
. I ended up welding the ends solid, I wanted a finished edge there. The top and bottom I stitch welded about every 2". Those seams will get seam sealer, plus the inside will get the matching bedliner. On to pics....
I still needed some way to attach the support straps, so I made some from angle...and tacked them in place
weld, weld, weld...I got a slight "oilcan" in the center....
grind, grind...take some time on this, it saves time later
here it is mounted with the cables installed....these cables are from an S-10..
. I like them because they have compact ends and are rubber covered. Maybe they won't chew up the paint.
another shot of the cables.....the bolts are temporary
Welding.......
A large flat panel like this is kinda tricky to weld....get it too hot and it will warp like a pretzel. Small welds, and move around alot. I even cool my welds with compressed air....well I did all that and it still warped a little...
. I ended up welding the ends solid, I wanted a finished edge there. The top and bottom I stitch welded about every 2". Those seams will get seam sealer, plus the inside will get the matching bedliner. On to pics....I still needed some way to attach the support straps, so I made some from angle...and tacked them in place
weld, weld, weld...I got a slight "oilcan" in the center....
grind, grind...take some time on this, it saves time later
here it is mounted with the cables installed....these cables are from an S-10..
. I like them because they have compact ends and are rubber covered. Maybe they won't chew up the paint.another shot of the cables.....the bolts are temporary
Lead Driver
Joined: Dec 2000
Posts: 6,289
Likes: 47
From: South central, Minnesota
LOL...yea, I used parts of a toilet seat hinge to hold the tailgate straps...I had forgot about those...LOL
Fordman75, have you looked at modifying a later model tailgate? I had thought about using the center section from a mid 80's stepside for awhile but then I decided I wanted to keep the Ford script center piece in mine.
Bobby
Fordman75, have you looked at modifying a later model tailgate? I had thought about using the center section from a mid 80's stepside for awhile but then I decided I wanted to keep the Ford script center piece in mine.
Bobby
I'm building the rest of my truck like a tank ( 10 gauge steel firewall, 14 gauge steel diamond plate floors, 16 gauge transmission tunnel, 10 gauge running boards, etc. ) So the box and tailgate are going to be similarly over built.
But I really like the looks of the stock 56 F250 tailgate. I'm still thinking on the Ford block lettering and the two raised ribs. I was thinking of a hammer form or something but it may be a little difficult to do in the heavier metal. Or I might just do some cut outs of the ribs and letting and just try to weld them onto a flat panel. But the hard part will be to get them clean looking with a nice blend.
Thread Starter
|
Welder User
Joined: Feb 2009
Posts: 5,269
Likes: 50
From: northwest MT
LOL...yea, I used parts of a toilet seat hinge to hold the tailgate straps...I had forgot about those...LOL
Fordman75, have you looked at modifying a later model tailgate? I had thought about using the center section from a mid 80's stepside for awhile but then I decided I wanted to keep the Ford script center piece in mine.
Bobby
Fordman75, have you looked at modifying a later model tailgate? I had thought about using the center section from a mid 80's stepside for awhile but then I decided I wanted to keep the Ford script center piece in mine.
Bobby
Sorry, I couldn't resist.......
Thread Starter
|
Welder User
Joined: Feb 2009
Posts: 5,269
Likes: 50
From: northwest MT
Got a question for you..
OK, now I need some input from you guys....
I cut the Ford script out of my old tailgate, and I want to mount it in the center of the new one. However, I am NOT going to cut a hole and attempt to weld it in. That would warp horribly and destroy my new gate. The script piece is kinda bent up, I've been beating on it and hope to flatten it out again.
So I'm thinking maybe I could use some panel adhesive? Any body have experience with this stuff? Or other ideas?
here is the script.....
cleaned up and sorta centered on the tail gate.
If this doesn't work, I may just have the script painted on.....
Let me know what you think!
I cut the Ford script out of my old tailgate, and I want to mount it in the center of the new one. However, I am NOT going to cut a hole and attempt to weld it in. That would warp horribly and destroy my new gate. The script piece is kinda bent up, I've been beating on it and hope to flatten it out again.
So I'm thinking maybe I could use some panel adhesive? Any body have experience with this stuff? Or other ideas?
here is the script.....
cleaned up and sorta centered on the tail gate.
If this doesn't work, I may just have the script painted on.....
Let me know what you think!
Lead Driver
Joined: Dec 2004
Posts: 7,669
Likes: 13
From: San Jose, CA
3M makes a panel bonding adhesive that is used to glue "weld" some body panels on newer vehicles. You can use that.
If it were me, I'd try to cut the letters out with a plasma cutter and glue them on individually.
Nice work!
If it were me, I'd try to cut the letters out with a plasma cutter and glue them on individually.
Nice work!
Roast em' if you got 'em
Joined: Mar 2005
Posts: 21,955
Likes: 9,727
From: Rio Rancho, NM
fordman75, for the lettering, you could use two panels, have the letters cut out of one panel and overlay it on the other panel. The letters would be a recess. I think CharlieLED did something similar on a customers truck;
https://www.ford-trucks.com/forums/9...lgate-art.html
tinman52, I know that the panel bonding adhesive is good stuff. My buddy, a bodyman was palyign with it years ago when it first started getting popular. He bonded a couple of pieces of sheet metal together, let it cure andthen tried to pull it apart. The metal gave and tore before the seam failed.
If you can get that piece with the script nice and flat and in a symetrical shape then I think bonding it with adhesive would work, either that or have someone paint it on
Nice work
Bobby
https://www.ford-trucks.com/forums/9...lgate-art.html
tinman52, I know that the panel bonding adhesive is good stuff. My buddy, a bodyman was palyign with it years ago when it first started getting popular. He bonded a couple of pieces of sheet metal together, let it cure andthen tried to pull it apart. The metal gave and tore before the seam failed.
If you can get that piece with the script nice and flat and in a symetrical shape then I think bonding it with adhesive would work, either that or have someone paint it on
Nice work
Bobby
FTE Stories
Ford Trucks for Ford Truck Enthusiasts
10 Best Ford Truck Engines We Miss the Most!
Joe Kucinski
2026 Shelby F-150 Off-Road: Better Than a Raptor R?
Brett Foote
2027 Super Duty Carhartt Package First Look: 12 Things You NEED to Know!
Michael S. Palmer
10 Most Surprising 2026 Ford Truck Features!
Joe Kucinski
Top 10 Ford Trucks Coming to Mecum Indy 2026
Brett Foote
5 Best / 5 Worst Ford Truck Wheels of All Time
Joe Kucinski
Ford Super Duty: 5 Things Owners LOVE, 5 Things They LOATHE!
Joe Kucinski
Every 2026 Ford Truck Engine RANKED from WORST to FIRST!
Michael S. Palmer
The Best F-150 Deal of Every Trim Level (XL through Raptor)
Joe Kucinski
Thread Starter
|
Welder User
Joined: Feb 2009
Posts: 5,269
Likes: 50
From: northwest MT
I should have mentioned that last pic of the script is not the final shape....
I was thinking an oval would look good, but now I'm thinking about cutting the letters out, as noted above.
You guys have some great ideas, keep them coming!
I was thinking an oval would look good, but now I'm thinking about cutting the letters out, as noted above.
You guys have some great ideas, keep them coming!
Lead Driver
Joined: Dec 2000
Posts: 6,289
Likes: 47
From: South central, Minnesota
If you decide to cut out the letters be careful depending on what you use to cut them out it can be really easy to mess up the letters.
Thread Starter
|
Welder User
Joined: Feb 2009
Posts: 5,269
Likes: 50
From: northwest MT
Part 4
Well, this tailgate project turned out to be more work than I had planned, which is typical. It would have been done by now, except.....
The script....had to think about this one for a while, but thanks to your input it worked out good
. I will let the pics explain....
This is the shape I ended up with....it took lots of file work
I used a panel adhesive from Evercoat called MAXIM....it came highly recommended...but spendy. I clamped it up an let it set over night.
I pulled the clamps next day.....hey that looks pretty good! Just needs a little filler to blend the edges.
And finally with some epoxy primer on it.
Still needs some filler primer and seam sealer, but hopefully will get paint in the next couple of weeks. Thanks for following along....Scott
The script....had to think about this one for a while, but thanks to your input it worked out good
. I will let the pics explain....This is the shape I ended up with....it took lots of file work
I used a panel adhesive from Evercoat called MAXIM....it came highly recommended...but spendy. I clamped it up an let it set over night.
I pulled the clamps next day.....hey that looks pretty good! Just needs a little filler to blend the edges.
And finally with some epoxy primer on it.
Still needs some filler primer and seam sealer, but hopefully will get paint in the next couple of weeks. Thanks for following along....Scott
