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Brat tailgate repair


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11 replies to this topic

#1 Godsmulligan

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Posted 24 April 2013 - 01:44 AM

Anyone that has fixed up a Brat has come across the conundrum, "Do I buy a new tailgate or fix the one I have?" I went with the latter.  Was it the right step? It was for me, but I was bored.

 

Below is the 12 step program I created, so you can see if it's worth it to you to repair your tailgate.

 

I also added a few pictures. Unfortunatly I'm missing a few pictures in the middle.

------------------------------------------------------------------------------------------------------------------------------------------

 

Step 1. Take out the components, of the tailgate

 

Step 2. Separate the two shells by cutting them with a grinder. (you can also unfold the edges and drill out the tack points, This is just the way I did it.)

 

Step 3. strip the paint (you wan't access to rump roast much rust as possible)

 

Step 4. use a wire wheel to take off all the rust

 

Step 5. Hit the bad spots with navel jelly

 

Step 6. Paint with rust stop.

 

step 7. hit the cancer with fiberglass ( I used netting and covered it in resin, as the whole top half of the tailgate was getting thin.)

 

Step 8. weld together (Careful when welding. If you get carried away, you will catch the fiberglass on fire ,and then you will have to recover the, now black carbon covered fabric.)

 

Step 9. grind welds. (Careful not to burn back through the metal)

 

Step 10. Fill body dents with filler, and fiberglass any remaining holes. ( I also used sheet metal to cover the biggest of the holes)

 

Step 11. Paint with rust stop again. Then with color of choice

 

Step 12. Re-install components

 

* Step 13. Have a beer



#2 Godsmulligan

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Posted 24 April 2013 - 02:08 AM

Attached File  1.jpg   75.51K   54 downloads

Attached File  2.jpg   141.02K   64 downloads

A good look at the cancer

Attached File  3.jpg   126.72K   52 downloads

This hole was later fit with a peice of sheet metal

Attached File  4.jpg   137.64K   49 downloads

The two halfs cut apart

Attached File  5.jpg   70.76K   49 downloads

If you look close you can see more cancer

Attached File  6.jpg   106.96K   45 downloads

Attached File  7.jpg   114.09K   31 downloads

 



#3 Godsmulligan

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Posted 24 April 2013 - 03:14 AM

missing the photos where I stripped, sanded and applied the fiberglass...



#4 Godsmulligan

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Posted 24 April 2013 - 03:22 AM

Here it is painted and welded back together.

Attached File  a.jpg   80.7K   28 downloads

You can see where I cut out the cancer and added some sheet metal.

Attached File  a1.jpg   83.74K   38 downloads

and again here

Attached File  a2.jpg   97.49K   34 downloads

This will have to be fiberglassed

Attached File  a5.jpg   118.6K   29 downloads

A closer look at the welds, already partially done.

Attached File  a3.jpg   85.72K   31 downloads

You can see some ofthe finer work that still needs to be done

Attached File  a4.jpg   87.69K   26 downloads



#5 Godsmulligan

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Posted 24 April 2013 - 03:25 AM

In body work, you are suppose to cut out all the cancer. If I did that with this tailgate, I would have nothing left...



#6 NickNakorn

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Posted 24 April 2013 - 02:05 PM

As for many of us 'cancer' is not just a word, perhaps you'd like to use the word 'rust' in future.



#7 Godsmulligan

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Posted 24 April 2013 - 02:49 PM

"Cancer" is a term for rust that has eaten all the way through the metal just as "retard" is a term for turning back your timing. What do you refer to them as across the pond?



#8 Godsmulligan

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Posted 29 April 2013 - 12:12 AM

Spent the last couple days adding fiberglass and body filler. I forgot what a pain in the rump roast fiberglass is. I didn't mix the resin strong enough so I had to recover it. Now I keep finding patches of pitch, it's awesome. It does work great on that cancer, though.



#9 Godsmulligan

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Posted 01 May 2013 - 11:32 PM

Finished the body work today...

Attached File  t.jpg   24.1K   14 downloads

Took more than I thought and it still needs more, but it's getting a coat of Herculiner when I finish the bed. That should cover up everything else.

Attached File  t1.jpg   26.42K   17 downloads

No more holes

Attached File  t2.jpg   18.33K   19 downloads

Here I cut out the cancer and welded in sheet metal, added fiberglass netting and resin, covered it in fiberglass body filler and topped it off with bondo. It's not as thick as it looks.

Attached File  t3.jpg   19.32K   16 downloads

painted the whole thing with Rustoleum and finished it off with satin black. letting it cure under the heat lamps over night before I paint the other side.

 

The satin black is "rattle can" and the tail gate is going to serve as a test. If I like it the whole car is getting rattle caned.



#10 turbosubarubrat

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Posted 01 May 2013 - 11:43 PM

did you leave drain wholes in the tail gate? if not you should drill some in the bottom, its the reason why these rust out so bad because they get clogged with stuff over years and they get wet inside and never dry out.



#11 Godsmulligan

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Posted 02 May 2013 - 12:20 AM

Thanks



#12 Godsmulligan

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Posted 04 May 2013 - 10:18 PM

Tailgate painted...

Attached File  IMG_1184.jpg   62.01K   14 downloads

 

I'll post a set of all the components back on it in a couple days, maybe I'll even buff the paint out. I doubt it though.

 

Attached File  IMG_1182.jpg   70.63K   14 downloads


Edited by Godsmulligan, 04 May 2013 - 10:20 PM.





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