Tailgate drain channel rust repair

Paint, bodywork and fabrication discussion.

Re: Tailgate drain channel rust repair

by Ray » Sun Sep 10, 2017 11:25 pm

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

by Ray » Sun Sep 10, 2017 11:27 pm

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

by Ray » Sun Sep 10, 2017 11:31 pm

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

by Ray » Sun Sep 10, 2017 11:32 pm

just another few freebie photos cos they look good.

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Re: Tailgate drain channel rust repair

by Ray » Sun Sep 10, 2017 11:36 pm

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

by Ray » Sun Sep 10, 2017 11:38 pm

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Re: Tailgate drain channel rust repair

by Ray » Sun Sep 10, 2017 11:38 pm

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Re: Tailgate drain channel rust repair

by Ray » Sun Sep 10, 2017 11:40 pm

and the final product...

happy to take questions.

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Re: Tailgate drain channel rust repair

by claysummers » Mon Sep 11, 2017 1:35 pm

Ray,
I've got two single daughters. Are you married?
Seriously that is outstanding.
Cheers
Clay


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Re: Tailgate drain channel rust repair

by EJ_VE_EH » Mon Sep 11, 2017 5:54 pm

Beautiful work Ray.
Very talented indeed !
 
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