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Re: Tailgate drain channel rust repair

PostPosted: Sun Sep 10, 2017 11:25 pm
by Ray
Now this part... hmmm took some thinking...

this took me about 4 hours to make this combination of tools/jigs to form the divots.

the tool consist of 2 main parts... again, the hard plastic i used for my first tool, and a stainless support plate.

the plastic backing in cut to the same profile as the trim. this was cut by hand, took a long time. once it was the correct profile, i used a hole saw to cut the "reverse divot" into it.

i then made a place to clamp the front, this ensured that my trim didn't move, and metal was forced to stretch.

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a bar was then used to flog the divots into shape.

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Re: Tailgate drain channel rust repair

PostPosted: Sun Sep 10, 2017 11:27 pm
by Ray
so they came up pretty good. very consistent across all divots.
super happy at this point.

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Re: Tailgate drain channel rust repair

PostPosted: Sun Sep 10, 2017 11:31 pm
by Ray
Now, back to work and used the press brake for the final 2 folds... again, careful selection of tool combination and press locations to ensure all dimension are correct for the final product.

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Re: Tailgate drain channel rust repair

PostPosted: Sun Sep 10, 2017 11:32 pm
by Ray
just another few freebie photos cos they look good.

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Re: Tailgate drain channel rust repair

PostPosted: Sun Sep 10, 2017 11:36 pm
by Ray
ok almost done, one more tool needed to be made. this was to put the recesses in the panel for the drain tube, so the rubbers sit down and the water can run out correctly...

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Re: Tailgate drain channel rust repair

PostPosted: Sun Sep 10, 2017 11:38 pm
by Ray
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Re: Tailgate drain channel rust repair

PostPosted: Sun Sep 10, 2017 11:38 pm
by Ray
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Re: Tailgate drain channel rust repair

PostPosted: Sun Sep 10, 2017 11:40 pm
by Ray
and the final product...

happy to take questions.

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Re: Tailgate drain channel rust repair

PostPosted: Mon Sep 11, 2017 1:35 pm
by claysummers
Ray,
I've got two single daughters. Are you married?
Seriously that is outstanding.
Cheers
Clay


Sent from my iPhone using Tapatalk

Re: Tailgate drain channel rust repair

PostPosted: Mon Sep 11, 2017 5:54 pm
by EJ_VE_EH
Beautiful work Ray.
Very talented indeed !