Weld-In Tailgate Handle Relocator How To

[BlazinLow_inORE]

Weld-In Tailgate Handle Relocator

I had a relocated tailgate handle on my trucks tailgate, an no sooner than it is installed, I get rearended by a full size chevy. Luckily since my truck is so low it was only my tailgate that got dented. At the time I had a ZR1 rollpan that got missed by about an inch.

Point being, I needed a new tailgate and that tailgate would need it's handle relocated. I wasn't crasy about how a relocation bracket looked so I decided to make a weld in relocator that will hopefully look slick.

http://buildyourride.com/98s10/weldhandle7.jpg (http://buildyourride.com/tech/relocator.jpg)
I started out making this bottom bracket from the tailgate handle relocator bracket plans on this website. Click on the picture to check them out.


http://buildyourride.com/98s10/weldhandle6.jpg
Next I sprayed primer on some sheet metal and used a screwdriver to scratch the bracket outline on the metal.

http://buildyourride.com/98s10/weldhandle5.jpg
Following the lines scratched on the metal, a jig saw was used to cut out the bracket.


http://buildyourride.com/98s10/weldhandle4.jpghttp://buildyourride.com/98s10/weldhandle3.jpg
Using a vise, the bracket was bent.

http://buildyourride.com/98s10/weldhandle2.jpghttp://buildyourride.com/98s10/weldhandle1.jpg
Bent bracket. http://buildyourride.com/98s10/weldhandle8.jpg
On the inside of the tailgate a hole was cut out following this template (http://buildyourride.com/tech/relocatortemp.doc).

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http://buildyourride.com/98s10/weldhandle9.jpg
On the outside of the tailgate the formed metal around the handle was cut out. This piece will be used on the inside of the tailgate.

http://buildyourride.com/98s10/weldhandle10.jpg
Here's a shot of how the bracket is orientated with the piece of metal that was just cut out from the outside of the tailgate.

http://buildyourride.com/98s10/weldhandle11.jpg
Now that hole needs to be filled. A rectangular piece of metal was cut out and welded into place. Magnets hold the metal in place and flush with the tailgate.

http://buildyourride.com/98s10/weldhandle12.jpg
Back to the inside of the tailgate, after the tailgate handle was bolted to the bracket, the bracket was welded in the hole on the inside of the tailgate. This is also the time to hook up the rods that go to the tailgate latches.

http://buildyourride.com/98s10/weldhandle13.jpg
Top View.

http://buildyourride.com/98s10/weldhandle15.jpg
Another. http://buildyourride.com/98s10/weldhandle14.jpg
This how the how the plastic trim piece will look once metal is welded in. Metal filler pieces will be welded to cover up the gaps.

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http://buildyourride.com/98s10/weldhandle18.jpg
Here is the metal ring and one filler panel welded in.

http://buildyourride.com/98s10/weldhandle16.jpg
Heres a shot of how the side filler panel looks.

http://buildyourride.com/98s10/weldhandle17.jpg
If the tailgate is closed and you look down, this is how the welded tailgate will appear.

http://www.buildyourride.com/98s10/weldinrelocator19.jpg
Here is the final product after grinding, bondo, sanding and paint. Sorry for the poor pictures. They don't do it justice. http://www.buildyourride.com/98s10/weldinrelocator20.jpg

[BlazinLow_inORE]

courtesy of...http://www.buildyourride.com/weldinrelocator.html