Tailgate drain channel rust repair

Paint, bodywork and fabrication discussion.

Tailgate drain channel rust repair

by Ray » Sun Sep 10, 2017 10:34 pm

So this is common area for rust in utes, vans and wagons.
My initial thought regarding this area was that it wasn't too bad. I have seen much worse and at the end of the day, could have been covered up and no one would ever have known. except me.
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This photo shows the area of concern. its not an easy place to access and to do it right. you need access.

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so, to get access. i started by unpicking the rear lower tailgate surround. This panel in itself was in remarkable condition and it was a hard decision to remove.
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Re: Tailgate drain channel rust repair

by Ray » Sun Sep 10, 2017 10:37 pm

so it took a lot of time to unpick this without damage, a 8mm spot weld drill was used.

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Re: Tailgate drain channel rust repair

by Ray » Sun Sep 10, 2017 10:40 pm

so these three pictures show how bad the rust was in this section. like i said, not overly bad, but i the rest of this car is in such great condition i wanted to have this area finished off correctly.

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Re: Tailgate drain channel rust repair

by Ray » Sun Sep 10, 2017 10:42 pm

so, next step was to remove the actual panel in question, again, more drilling. but it came off without further damage.

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Re: Tailgate drain channel rust repair

by Ray » Sun Sep 10, 2017 10:46 pm

Again, a few pictures to show the extent of the rust in this panel.

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Re: Tailgate drain channel rust repair

by Ray » Sun Sep 10, 2017 11:00 pm

Now once i had this removed. my plan was to perform a few careful cuts, shape a few small sections and weld in the new rust free sections.

but as everyone knows. where do you stop... when I started to do some sample forms in some sheet metal to fill the rust holes. I figured i wasn't far off having all the ingredients to make the whole thing.

So. i got started at making the whole thing, from scratch, from 1.2mm cold rolled sheet.

I started with a forming buck that I made at work. Its a 12mm plate, welded to another 12mm plate. the top plate is cut to the correct radius required... I also added a 2mm radius to the edge (by hand with angle grinder)

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this is a forming block i made from 25mm hard plastic (not exactly sure of the specs some kind of high impact wear stuff)

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I then placed my rough cut sheet of 1.2 on the top of my buck with a 8mm plate on top to ensure nothing moved... probably bit of an over kill really, but i have never done anything like this so as people do when they have never done something, they over engineer.

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Re: Tailgate drain channel rust repair

by Ray » Sun Sep 10, 2017 11:03 pm

using my plastic tool as a forming dolly, I avoided any hammer and dolly marks on the sheet, once finished it was very nice consistent shape with no tool marks.
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Re: Tailgate drain channel rust repair

by Ray » Sun Sep 10, 2017 11:10 pm

So it took about 45min-1 hour just to tap this sheet into shape... sharing the hammer swinging with Dad helped save my arm.

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we now have the compound fold/step and something to continue on with...
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making the buck/jig/tools - made at work on laser cutter/waterjet. 3-4 hours just in making these and thinking about all the things that needed to me thought about.

tapping sheet into place once buck was made - 45-60min.

total time at this point. about 5 hours or so, no including pulling the car apart.
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Re: Tailgate drain channel rust repair

by Ray » Sun Sep 10, 2017 11:13 pm

So just a few more pics to show how nice the shape is so far
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Re: Tailgate drain channel rust repair

by Ray » Sun Sep 10, 2017 11:17 pm

So the next step was to take the panel to work, and use the press brake to do a couple nice straight folds
this took about an hour or two... most the time was taken doing samples of fold locations and tooling combinations to achieve the correct radius on each fold. at this point the profiles match perfectly.
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