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Thanks. Just thought that I would close out this thread with a pic from the F100 Western Nationals of the finished truck and its owner. Sorry about all the reflections in the photo, it was the best one I could download...
I have had a few questions regarding the technique I used on this tailgate and how I had the insert waterjetted. The attached photo shows the tailgate just after I bonded the new waterjetted panel on top of the original tailgate insert. The black along the edges of the lettering is the panel adhesive (3M 08115). As you can see, the upper edge and the sides of the new insert butt against the existing spot welded flanges on the tailgate. The whole reason for placing this panel on the tailgate in the first place was to eliminate the "steps" in the original tailgate insert...the lettering was just a "target of opportunity" that arose during the process.