BlazinLow_inORE
12-19-04, 01:48 AM
Installing a
Tailgate Handle Relocator
http://www.buildyourride.com/98s10/relocator1.jpg
Installing a tailgate handle relocator is no big deal. Here we will be installing one on a 98 S10. All you need is some torx bit drivers, screwdriver, drill and jigsaw. Here is a picture of the front and back of the relocator. I took measurements before it was installed so that it could be reproduced later. The plans are available here. (http://www.buildyourride.com/tech/relocator.jpg)
http://www.buildyourride.com/98s10/relocator3.jpg
The first step was to remove the tailgate from the truck and lay it on a pair of saw horses or work bench. Next remove the plastic trim from around the handle. There are 2 tabs on each of the long sides holding it to the metal. It's easy to remove with a screwdriver. Turn the tailgate over and remove the 3 torx bolts that are holding the handle on. With the same torx bit unscrew the bolts holding the latches on each side of the tailgate. Flip the tailgate over again and remove the 2 rods, one from each latch, that hook into the handle, remove these by pushing the plastic tab carefully off the rod (red arrow), then pulling the rod (green arrow) straight out of the handle.
http://www.buildyourride.com/98s10/relocator2.jpg
Next lay out this template (http://www.buildyourride.com/tech/relocatortemp.doc) on the tail gate, lining up the 2 holes on the template with 2 bolt holes from the handle bolts. Trace out the dotted rectangle on the template. Drill 5/16" holes inside each corner of the rectangle and cut it out with a jigsaw.
http://www.buildyourride.com/98s10/relocator4.jpg
Next install the handling into the relocation bracket, only use 2 of the mounting screws, otherwise it will dent the outside of the tailgate when you put the bracket into the tailgate. The handle is threaded and installation is quite easy.
http://www.buildyourride.com/98s10/relocator5.jpg
The latches were taken out for a reason, the rods have to be switched. The rod from the right latch has to be put on the left latch and vice versa. The handle side of each rod has a 90 degree bend in it. These have to be facing down, with your latches in the orientation they would be if they were in the tailgate and the hole you just cut in the tailgate is facing up. I know that sentence is hard to understand but it is important that the rods are in this orientation. Later on when you put the latches back in and the rod end if facing up then you have to flip(not switch) the rods so they point down.
Next reinstall the latches. Then press the rods back into there holes on the handle. This is kind of tricky since the bracket is big and gets in the way. Its not impossible.
http://www.buildyourride.com/98s10/relocator6.jpg
Once the rods are attached to the handle, push the plastic tabs back over the rods. Then predrill and attach the bracket to the tailgate with sheet metal screws. Check to make sure the handle pulls the latches in. If everything is ok then reinstall the plastic handle cover.
http://www.buildyourride.com/98s10/tailgatehandlefillerground.jpg
Next, cut and weld in a peice of metal into the hole in the front of the tailgate. Grind, bondo, sand, primer and paint your way to happiness.
Tailgate Handle Relocator
http://www.buildyourride.com/98s10/relocator1.jpg
Installing a tailgate handle relocator is no big deal. Here we will be installing one on a 98 S10. All you need is some torx bit drivers, screwdriver, drill and jigsaw. Here is a picture of the front and back of the relocator. I took measurements before it was installed so that it could be reproduced later. The plans are available here. (http://www.buildyourride.com/tech/relocator.jpg)
http://www.buildyourride.com/98s10/relocator3.jpg
The first step was to remove the tailgate from the truck and lay it on a pair of saw horses or work bench. Next remove the plastic trim from around the handle. There are 2 tabs on each of the long sides holding it to the metal. It's easy to remove with a screwdriver. Turn the tailgate over and remove the 3 torx bolts that are holding the handle on. With the same torx bit unscrew the bolts holding the latches on each side of the tailgate. Flip the tailgate over again and remove the 2 rods, one from each latch, that hook into the handle, remove these by pushing the plastic tab carefully off the rod (red arrow), then pulling the rod (green arrow) straight out of the handle.
http://www.buildyourride.com/98s10/relocator2.jpg
Next lay out this template (http://www.buildyourride.com/tech/relocatortemp.doc) on the tail gate, lining up the 2 holes on the template with 2 bolt holes from the handle bolts. Trace out the dotted rectangle on the template. Drill 5/16" holes inside each corner of the rectangle and cut it out with a jigsaw.
http://www.buildyourride.com/98s10/relocator4.jpg
Next install the handling into the relocation bracket, only use 2 of the mounting screws, otherwise it will dent the outside of the tailgate when you put the bracket into the tailgate. The handle is threaded and installation is quite easy.
http://www.buildyourride.com/98s10/relocator5.jpg
The latches were taken out for a reason, the rods have to be switched. The rod from the right latch has to be put on the left latch and vice versa. The handle side of each rod has a 90 degree bend in it. These have to be facing down, with your latches in the orientation they would be if they were in the tailgate and the hole you just cut in the tailgate is facing up. I know that sentence is hard to understand but it is important that the rods are in this orientation. Later on when you put the latches back in and the rod end if facing up then you have to flip(not switch) the rods so they point down.
Next reinstall the latches. Then press the rods back into there holes on the handle. This is kind of tricky since the bracket is big and gets in the way. Its not impossible.
http://www.buildyourride.com/98s10/relocator6.jpg
Once the rods are attached to the handle, push the plastic tabs back over the rods. Then predrill and attach the bracket to the tailgate with sheet metal screws. Check to make sure the handle pulls the latches in. If everything is ok then reinstall the plastic handle cover.
http://www.buildyourride.com/98s10/tailgatehandlefillerground.jpg
Next, cut and weld in a peice of metal into the hole in the front of the tailgate. Grind, bondo, sand, primer and paint your way to happiness.