1. Welcome to Tacoma World!

    You are currently viewing as a guest! To get full-access, you need to register for a FREE account.

    As a registered member, you’ll be able to:
    • Participate in all Tacoma discussion topics
    • Communicate privately with other Tacoma owners from around the world
    • Post your own photos in our Members Gallery
    • Access all special features of the site

DIY Tailgate Inner Panel Cover?

Discussion in '2nd Gen. Tacomas (2005-2015)' started by steveo27, Feb 7, 2020.

  1. Feb 9, 2020 at 11:55 AM
    #21
    Key-Rei

    Key-Rei Well-Known Member

    Joined:
    Jun 20, 2017
    Member:
    #221942
    Messages:
    2,610
    First Name:
    Key
    Florida
    Vehicle:
    2010 TRD Off-Road 6Spd 4x4 209BSM
    Locker anytime Fog Lights anytime Full LED light conversion TRD cat back Rear cat delete Exaust Y reroute away from actuator Alloy Clutch master 2000 4Runner "Dog Leg" shift leaver Marlin shift seats and bushing Rear seat delete Rear diff breather extension Chrome grille swap Debadge Rear seat delete Honda blower motor beefy plug and wire mod Anytime 12v and USB with volt gauge in bed Blue Sea fuse box Hella AND 70's Caddy horns Low profile recessed hex drain plug swaps Alluminum battery strap 7pin relocated Backup cam on anytime Various other creature comfort and personal taste mods.
    Went to the junkyard found a K body with an aluminum tailgate skin, yanked it, trimmed 4" or so off one side, ripped the plastic crap expanding square "nuts" out of the tailgate skin and replaced them with 1/4-20 riv-nuts, reglued the inner tailgate frame to the back of the outer skin with structural 2 part apoxy adhesive, coated the mating surfaces with FIPG, drilled new holes in the diamond plate skin, affixed with stainless "sidewalk" bolts.

    BAM:
    IMG_20190609_145307.jpg


    Cost me like tree-fiddy.
     
    spitdog likes this.
  2. Feb 9, 2020 at 11:58 AM
    #22
    Islandtaco671

    Islandtaco671 Well-Known Member

    Joined:
    Nov 21, 2017
    Member:
    #236611
    Messages:
    412
    Gender:
    Male
    First Name:
    Daniel
    San Diego
    Vehicle:
    2006 Double cab Tacoma TRD O/R
    I had the advantage of working for a sheet metal shop at the time. Made the longer cuts on the shear and the sides I got em on a bandsaw
     
  3. Feb 9, 2020 at 12:57 PM
    #23
    Bajatacoma

    Bajatacoma Well-Known Member

    Joined:
    Dec 10, 2010
    Member:
    #47503
    Messages:
    1,252
    Gender:
    Male
    SC
    Vehicle:
    05 TRD SR5

    You can cut aluminum with a carbide tipped wood cutting blade. It's messy (wear your PPE, especially safety glasses) and it's not great for the blade but it'll work fine for most home shop type work. Better still, buy a metal cutting blade; Diablo for example makes versions for circular saws, angle grinders, etc. Ex. https://www.diablotools.com/explore/saw-blades

    Check your yellow pages for metal sales, especially recyclers. Recyclers can be hit or miss depending on what they have on hand but they usually sell by weight, not shape. Some of them will have shears and brakes and will do cuts and bends for you for a price. There is also a chain of stores called Metal Supermarket that may be in your area (they closed here unfortunately). The big box stores are generally way overpriced on metal.

    If you're going to go steel or even if you are planning on replacing the factory piece I'd install rivnuts/nutsert/whatever you want to call them. The cheap plastic inserts that Toyota uses will strip out and not hold secure after you remove the fasteners a time or two (seeing a pattern here yet? Toyota went CHEAP on a lot of stuff).
     
    Last edited: Feb 9, 2020
  4. Feb 10, 2020 at 2:27 PM
    #24
    RelentlessFabrication

    RelentlessFabrication relentlessfabrication.com Vendor

    Joined:
    Sep 12, 2018
    Member:
    #266012
    Messages:
    215
    Sparks, NV
    This won't make it $20 but if you do decide to purchase one of our Tail Gate Reinforcement Plates be sure to use the coupon code below as it will save you some additional $$ :thumbsup:

    TW10OFF: Save $10 off all Tacoma products, no min.

    Relentless Fabrication
    www.relentlessfabrication.com
     
    DG92071 and stickyTaco like this.
  5. Feb 11, 2020 at 5:33 PM
    #25
    solmooth

    solmooth Well-Known Member

    Joined:
    Oct 6, 2019
    Member:
    #307206
    Messages:
    52
    Gender:
    Male
    San Jose, CA
    Vehicle:
    '19 DCLB OR Cement
    wallygatoresq likes this.
  6. Feb 13, 2020 at 3:38 PM
    #26
    steveo27

    steveo27 [OP] Ask me about my weiner

    Joined:
    Aug 12, 2013
    Member:
    #110326
    Messages:
    4,851
    Gender:
    Male
    First Name:
    Steve
    Pittsburgh
    Vehicle:
    '11 TRD Off Road & 1992 VW GLI
    The same shit everyone else has.
    upload_2020-2-13_18-37-54.jpg

    HDPE showed up today.

    New new hardware inserts showed up too

    I’ll start on it tomorrow
     
    outxider likes this.
  7. Feb 13, 2020 at 3:42 PM
    #27
    tathambenjamin

    tathambenjamin Well-Known Member

    Joined:
    Jun 29, 2017
    Member:
    #222703
    Messages:
    235
    Gender:
    Male
    First Name:
    ben
    Vehicle:
    2008 4Runner SR5
    -2.5/1.5 spacer lift -270/65/17 Cooper AT3
    following this closely- would like to do the same with mine.
     
    steveo27 [OP] likes this.
  8. Feb 13, 2020 at 5:12 PM
    #28
    steveo27

    steveo27 [OP] Ask me about my weiner

    Joined:
    Aug 12, 2013
    Member:
    #110326
    Messages:
    4,851
    Gender:
    Male
    First Name:
    Steve
    Pittsburgh
    Vehicle:
    '11 TRD Off Road & 1992 VW GLI
    The same shit everyone else has.
    Ill try to keep this thread going with some info. If not, it’ll all be in my build thread for sure.
     
  9. Feb 14, 2020 at 3:43 PM
    #29
    steveo27

    steveo27 [OP] Ask me about my weiner

    Joined:
    Aug 12, 2013
    Member:
    #110326
    Messages:
    4,851
    Gender:
    Male
    First Name:
    Steve
    Pittsburgh
    Vehicle:
    '11 TRD Off Road & 1992 VW GLI
    The same shit everyone else has.
    Done and done.

    upload_2020-2-14_18-41-10.jpg

    upload_2020-2-14_18-41-24.jpg

    upload_2020-2-14_18-41-49.jpg

    upload_2020-2-14_18-43-23.jpg

    upload_2020-2-14_18-43-37.jpg

    99% happy with it. The bottom edge is about 1/8” too long and it binds the slightest bit when shutting the tailgate.

    I’m gonna pull it off tomorrow and rip an 1/8” off that edge then install the new screw retainers and install it for good.

    I may explore the option of countersunk hardware down the sides and along the bottom.
     
    Last edited: Feb 14, 2020
  10. Feb 14, 2020 at 3:43 PM
    #30
    Islandtaco671

    Islandtaco671 Well-Known Member

    Joined:
    Nov 21, 2017
    Member:
    #236611
    Messages:
    412
    Gender:
    Male
    First Name:
    Daniel
    San Diego
    Vehicle:
    2006 Double cab Tacoma TRD O/R
    Looks good OP!
     
  11. Feb 14, 2020 at 3:45 PM
    #31
    tathambenjamin

    tathambenjamin Well-Known Member

    Joined:
    Jun 29, 2017
    Member:
    #222703
    Messages:
    235
    Gender:
    Male
    First Name:
    ben
    Vehicle:
    2008 4Runner SR5
    -2.5/1.5 spacer lift -270/65/17 Cooper AT3
    Looks nice- you happen to have a link to the place you bought the hdpe?
     
  12. Feb 14, 2020 at 3:50 PM
    #32
    steveo27

    steveo27 [OP] Ask me about my weiner

    Joined:
    Aug 12, 2013
    Member:
    #110326
    Messages:
    4,851
    Gender:
    Male
    First Name:
    Steve
    Pittsburgh
    Vehicle:
    '11 TRD Off Road & 1992 VW GLI
    The same shit everyone else has.

    https://www.ebay.com/itm/142754668242

    It’s 24”x54” I wish it was a 55”.

    upload_2020-2-14_18-54-27.jpg


    You can see it’s about 1/2” shorter than ideal on each side.


    The next size up is 24”x48” but the extra cost wasn’t worth it to me.

    eBay is the only place I’ve found with free shipping on hdpe. They have 3/8” and 1/2” as well I believe
     
    Last edited: Feb 14, 2020
  13. Feb 14, 2020 at 4:00 PM
    #33
    BalutTaco

    BalutTaco Moja_Przygoda

    Joined:
    Apr 2, 2019
    Member:
    #288885
    Messages:
    1,008
    Gender:
    Male
    Vehicle:
    3rd Gen 2019 Cement DCLB TRD OR
    265/75r/16 Ko2 / Bird nest engine bay.../
    Came out very nice OP!!! Love the beer holder as well!! Time to toss my ply wood and get me some HDPE !!!

    Maybe i'll take out my tailgate panel and trace it!!! onto the HDPE.
     
    steveo27 [OP] likes this.
  14. Feb 14, 2020 at 4:07 PM
    #34
    steveo27

    steveo27 [OP] Ask me about my weiner

    Joined:
    Aug 12, 2013
    Member:
    #110326
    Messages:
    4,851
    Gender:
    Male
    First Name:
    Steve
    Pittsburgh
    Vehicle:
    '11 TRD Off Road & 1992 VW GLI
    The same shit everyone else has.
    Thanks. Cup holders are an essential part of camping.

    That’s all I did. Traced it and cut out.

    The only issue using the oem panel as a template is the bottom edge hangs down too far.

    The tailgate won’t shut because the HDPE is a little thicker than the oem panel so I had to rip 1/2“ off that edge to make it fit. It still binds a tiny bit and I plan on ripping another 1/8” off of it it to remedy this.

    So all said and down, the bottom edge will be 5/8” short than the oem panel.

    You could probably cut the bottom edge with a 45* bevel and it would fit without ripping it. Or if you wanted to get fancy, you could hit the whole thing with a router.

    I chose to rip it and keep the 90* edge since no other edge is beveled
     
    Last edited: Feb 14, 2020
    BalutTaco likes this.
  15. Feb 14, 2020 at 4:11 PM
    #35
    BalutTaco

    BalutTaco Moja_Przygoda

    Joined:
    Apr 2, 2019
    Member:
    #288885
    Messages:
    1,008
    Gender:
    Male
    Vehicle:
    3rd Gen 2019 Cement DCLB TRD OR
    265/75r/16 Ko2 / Bird nest engine bay.../
    Thanks for saving me $150 lol!! I'll just slap a mount hatch sticker on it and call it a day! LOL
     
    steveo27 [OP] likes this.
  16. Feb 14, 2020 at 4:28 PM
    #36
    steveo27

    steveo27 [OP] Ask me about my weiner

    Joined:
    Aug 12, 2013
    Member:
    #110326
    Messages:
    4,851
    Gender:
    Male
    First Name:
    Steve
    Pittsburgh
    Vehicle:
    '11 TRD Off Road & 1992 VW GLI
    The same shit everyone else has.
    Haha. Yeah.

    The Mountain Hatch piece is nice, but not 230$ nice
     
    BalutTaco likes this.
  17. Feb 15, 2020 at 6:18 AM
    #37
    tathambenjamin

    tathambenjamin Well-Known Member

    Joined:
    Jun 29, 2017
    Member:
    #222703
    Messages:
    235
    Gender:
    Male
    First Name:
    ben
    Vehicle:
    2008 4Runner SR5
    -2.5/1.5 spacer lift -270/65/17 Cooper AT3
    Thinking about doing this and buying one of the kB voodoo metal lips for the top edge...

    how do you feel about the 1/4 in thickness? Does it add any strength or weight to things or about the same as stock?
     
  18. Feb 15, 2020 at 6:32 AM
    #38
    Yann

    Yann Well-Known Member

    Joined:
    Oct 6, 2018
    Member:
    #268498
    Messages:
    640
    Gender:
    Male
    First Name:
    Mick
    South Carolina
    Vehicle:
    98 Base I4 4x2 / 18 SR V6 4x4
    A/C Drain Pro Grille Intermittent Wipers Blacked out Wheels Blacked out Badges Gasshole Nfab Predator Bars Tweeter Upgrade Morimoto Amber LED Fog Lights Meso fuse box Stage 1 taillights
    Which plastics place did you go to? I'm also in SC, seems like shipping is a killer.
     
  19. Feb 15, 2020 at 8:07 AM
    #39
    GREENBIRD56

    GREENBIRD56 Well-Known Member

    Joined:
    Aug 19, 2014
    Member:
    #136508
    Messages:
    390
    Gender:
    Male
    First Name:
    Steve
    Casper / Tucson
    Vehicle:
    014 Taco 4Dr 4wd
    One thing different I did with mine - lay out centers for an additional rivnut into the center of the internal cross bars. Mostly was thinking it would help avoid rattling on a rutted FS road.
     
    steveo27 [OP] likes this.
  20. Feb 15, 2020 at 8:21 AM
    #40
    steveo27

    steveo27 [OP] Ask me about my weiner

    Joined:
    Aug 12, 2013
    Member:
    #110326
    Messages:
    4,851
    Gender:
    Male
    First Name:
    Steve
    Pittsburgh
    Vehicle:
    '11 TRD Off Road & 1992 VW GLI
    The same shit everyone else has.
    That’s not a bad idea at all. I may explore that using sountersunk hardware if need be.



    No additional strength or weight. I wouldn’t do jumping jacks on it, but standing on it was fine. It does flex a tiny tiny little bit.

    You could use thicker HDPE but you’d have to router the edges down to 1/4” where it meets the edge of the bed similar to how the Mountain Hatch is. Or cut a smaller piece of HDPE so it doesn’t quite extend out as far, but you’d lose the oem mounting holes.
     
    Last edited: Feb 15, 2020

Products Discussed in

To Top