How I'm fixing my flexy tailgate...

Spot on Canyonchaser!

I bent out the lip using a VERY large crescent wrench, as in 24" or so. I think I got it at Harbor Freight.

 

I started doing that, but it was making the lip wavy, so I resorted to the long block of wood to get a more even result. I'd imagine a little bit of heat would facilitate the bending.

dp

 

Shipped out another one today. Down to 2 left:

$125, $---, $100, $---

 

And then there was one...

$125

 

Can you tell me what size torque socket I need to remove the plastic on the tailgate?

 

Just realized what a pile of shit this tailgate really is after inspecting the strength of mine. Toyota sure didn't pull out all the stops on this one.

 

Torx T30.

 

works well, I picked mine up and just installed yesterday. Looks great and the door is solid. Just got to be careful with opening the gate ( not to drop it on the cables ). I didn't even have to adjust the latches all I did was remove the rubber stopper.

 

That looks great! What did you use to cover the tailgate??

 

I have mine installed. Ended up not using the plastic. I also am currently only using bolts on the four corners. Not sure if I will use them all, seems like less holes to worry about rusting. I will post a picture later. Mine does not look as good as sytfu510. I might look to get is stripped later re-done like that one.

I will tell you best mod thus far. The tailgate seems 500% stronger than prior. Also seems the added weight helps with traction on the roads around here.

 

just bought the last one. any additional pointers on install would be appreciated. Not sure how the hell i'm going to bend out the middle on this thing without messing it up royally. thanks.

 

Thanks, all I did was sand and primer the metal, then used the "spray on" bed liner from the auto parts store. Came out great and the can was only $6 and I still had plenty left. Held up pretty dam good thus far with some loading and unloading of bikes. FYI I also put painters tape over the top half of the tailgate to help prevent scratches when installing/removing. Then I just yanked the tape out from the bottom after installing the plate.

 

This looks like a great idea. Too bad you might not make more. If these were made a and sold by a reputable vendor on a regular basis I'd definitely buy one.

 

Just got mine installed last weekend. Did it about the same as the OP only instead of shaving off mm's of the metal sheet i shaved down the bump on the underside of the plastic cover. I used the duplicolor spray on bedliner and it went on pretty easily but i already scratched a big piece of it off. I'll have to touch it up and be more careful with it from now on. Also, the tailgate is ridiculously sturdy now but really heavy. My mom couldn't even shut the thing. Thanks for the Guidance OP!

 

If there's enough interest, I may do another run. Let me ask, though, *if* I did another run, would you want me to keep them simple and cheap as they are, or make improvements (that will increase the cost) such as:

- Pre-drilling the holes
- Primering
- Weight savings such as dimpling
- (I'll look back through the threads and get other ideas.)

 

I'm working on getting things arranged with a sheet metal forming shop now, so these should finally be available from me soon as well.

 

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I really liked what you made ... but aluminum would have been a better option for me and my needs. I know that aluminum would cost more.

FWIW ... I ordered some 3" x 5" x 3/8" aluminum angle (6061-T6) today to put on top of my tailgate. Later, I will order some 1/4" or 3/8" aluminum plate to bolt to the tailgate. It won't look as good as what you did, but I have no metal fabrication tools available to me now.

If you could do your project in aluminum plate ... I think you could easily get $250.00 to $300.00 and up out of them. But even at that price, the aluminum (depending on your source) may still be too expensive ... just thinking out loud now.
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1/8" aluminum is what I made my original out of back in 2007, and what I will make the production ones out of as well. It held up to my years of abuse with absolutely no issues so no need for anything thicker or heavier.

 

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.... Thanks for the info. ... when will you make them ??? ....
.

 

Soon. Just finding a forming shop that can do the little 45/45 jog bend in the plate, then they'll be available.
Already have both the 1st and 2nd gen tailgate plates all CAD drawn so just waiting on that final detail before I get some CNC cut.