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My Tailgate Reinforce Project

Discussion in '2nd Gen. Tacomas (2005-2015)' started by Cars0n`, Mar 1, 2010.

  1. Mar 1, 2010 at 6:11 PM
    #1
    Cars0n`

    Cars0n` [OP] Well-Known Member

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    Carson
    Edmonton AB
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    07 2wd access cab base.
    Kenwood DDX-512 Deck, Boston Acoustics G5 Sub in Ported Bassworx Box, Kenwood eXcelon KAC-X10D Amp, Sirius Satellite Radio, Magellan GPS, DDM 55w bi-xenon headlights, 2 HID Hella 500ff's mounted behind grill, 4 pc ebay Billet grill, Fog Lights (my truck didnt have them stock), Pioneer Speakers 6x9's(front) 6.5's(rear) AFE Cold Air Intake, Hose Clamp Mod, Tailgate Strengthen Mod, Removed Gay Mud Flaps, De-Badged, BHLM, 245/45/20 on velocity wheels. VW865a, Extra D Rings In Box, OEM Cruise Added Optima Red Top Battery
    my tailgate was bent for some time so i fugured i would do the reinforcement mod to it. this is just showing how i did mine.

    *** please do not trust my measurements because placing of your metal supports may differ. also i am not held responsible if someone tries this and screws up their tailgate or hurts themselves etc.. THIS IS FOR ILLUSTRATION PURPOSES ONLY*****

    here is the thread for the story on my tailgate being bent..
    http://www.tacomaworld.com/forum/2nd-gen-tacomas/76967-so-i-cleaned-my-truck-found.html

    i am aware there is already a how-to on doing this mod, im just showing how mine was done
    now onto the reinforcement...

    things you may neeed:
    drill with drill bits for the corresponding screw size
    more drill bits of the same size, (i broke off about 6 so far and im half done)
    cutting oil
    screws or bolts, i used #8 x 3/4" self tapping metal screws
    washers for screws
    clamps
    grinder
    angle iron or other supporting metal. i used 1"x1"x3/16" angle iron
    horizontal supports are roughly 52" long (x2)
    vertical supports are roughly 14.5" long (x6)
    epoxy or goop to re-fasten the stock supports to the tailgate


    used a piece of old bed frame for the bottom where the tailgate pivots because this is the weakest metal i had and that is where the tailgate needs the least support

    [​IMG]

    Had to grind off the legs

    [​IMG]

    after that i test fitted and maneuvered it into place. this was kinda tricky but definately possible. BUT the length of the piece should not be longer than 52", i dont think you could get it in there with much more length.

    keep in mind this is just showing how this piece is facing under the bottom lip of the tailgate, not where i actually placed it.

    [​IMG]

    after i test fitted and was happy with the position i screwed it into place, notice the 4 silver screws with washers along the bottom edge.

    [​IMG]

    view from the top looking down at the bottom piece.

    [​IMG]

    now onto the top

    refrence of how bent it is, after i straightened it out a bit by hand.

    [​IMG]

    test fitting top piece. had to cut it again to get it in there, it was a little too long.

    [​IMG]

    here was the tricky part. where the tailgate was bent i knew it would be hard to get the straight piece of angle iron in there so i figured i would use the leverage of the angle iron to get the second screw in, so i put the first screw in on the side with the smallest portion of the tailgate on the side of the bend (roughly 1/3 of the gate is on the right of the bend, and the other 2/3 is on the left), in my case it was the right side looking from the rear. if that makes any sense. with that screw in i figured it would be easier to press the longer piece of angle iron onto the rest of the tailgate lip and screw into place.

    i managed to get it in there using a scrap piece of metal as a spacer to press the angle iron down into the groove where it should sit, and the large screw driver to force it snug against the lip of the tailgate so i could drill a hole to screw it on.

    [​IMG]

    with the 2 end screws in i proceeded to put the rest of the screws in the tailgate on the top. this is a refrence of how much straighter it is now.

    [​IMG]

    now onto the middle supports. i put the angle iron the way i did (one side on the tailgate lip facing up (where i screwed into) and one side facing the middle of the tailgate) so i could weld the vertical middle supports to the top and bottom horizontal supports when i have everything all screwed together.

    the measurements for these middle supports come out to be about 14 1/4" so the fit snug between the 2 top and bottom pieces.

    i only got 2 of the 6 cut and fit tonight but i will finish it all off tomorrow hopefully.

    [​IMG]

    ill update my progress tomorrow
     
  2. Mar 1, 2010 at 6:15 PM
    #2
    brians05taco

    brians05taco Well-Known Member

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    Lafayette,La.
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    05 prerunner white debadged 4.0
    lifted, bedcover,BHLM, grill, etc...
    i pitty the person that rams u lol lookin good think my tailgate could use some help kinda weird when u sit two or three people on there while open
     
  3. Mar 1, 2010 at 6:32 PM
    #3
    Cars0n`

    Cars0n` [OP] Well-Known Member

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    Carson
    Edmonton AB
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    07 2wd access cab base.
    Kenwood DDX-512 Deck, Boston Acoustics G5 Sub in Ported Bassworx Box, Kenwood eXcelon KAC-X10D Amp, Sirius Satellite Radio, Magellan GPS, DDM 55w bi-xenon headlights, 2 HID Hella 500ff's mounted behind grill, 4 pc ebay Billet grill, Fog Lights (my truck didnt have them stock), Pioneer Speakers 6x9's(front) 6.5's(rear) AFE Cold Air Intake, Hose Clamp Mod, Tailgate Strengthen Mod, Removed Gay Mud Flaps, De-Badged, BHLM, 245/45/20 on velocity wheels. VW865a, Extra D Rings In Box, OEM Cruise Added Optima Red Top Battery
    yeah i couldnt stand on it without it flexing under my feet so i said to hell with this lol.

    with just the 2 bars i have in there now its significantly heavier. mmmm :)
     
  4. Mar 1, 2010 at 7:04 PM
    #4
    olgzr

    olgzr Well-Known Member

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    I just bought a 2010 Prerunner. Has Toyota reinforced the tailgates since yours was built or do I need to reinforce it before it gets bent? Thanks.
     
  5. Mar 1, 2010 at 7:40 PM
    #5
    DOERanger

    DOERanger Well-Known Member

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    Knoxville, TN
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    2010 DC Sport SB
    No Mudflaps, Fog lights on all the time, Map light/Dome light mod, Door sill protectors, In-channel window guards, Re-badged and sock-monkeyed,many more to come.
    Toyota has not reinforced it.
     
  6. Mar 2, 2010 at 7:52 AM
    #6
    Cars0n`

    Cars0n` [OP] Well-Known Member

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    07 2wd access cab base.
    Kenwood DDX-512 Deck, Boston Acoustics G5 Sub in Ported Bassworx Box, Kenwood eXcelon KAC-X10D Amp, Sirius Satellite Radio, Magellan GPS, DDM 55w bi-xenon headlights, 2 HID Hella 500ff's mounted behind grill, 4 pc ebay Billet grill, Fog Lights (my truck didnt have them stock), Pioneer Speakers 6x9's(front) 6.5's(rear) AFE Cold Air Intake, Hose Clamp Mod, Tailgate Strengthen Mod, Removed Gay Mud Flaps, De-Badged, BHLM, 245/45/20 on velocity wheels. VW865a, Extra D Rings In Box, OEM Cruise Added Optima Red Top Battery
    i thought they did??

    im sure there is an answer somewhere on this site.
     
  7. Mar 2, 2010 at 7:57 AM
    #7
    DOERanger

    DOERanger Well-Known Member

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    No Mudflaps, Fog lights on all the time, Map light/Dome light mod, Door sill protectors, In-channel window guards, Re-badged and sock-monkeyed,many more to come.
    I'm pretty sure but I could be wrong.
     
  8. Mar 2, 2010 at 7:58 AM
    #8
    eordonez

    eordonez Living vicariously through mjp2

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    OEM All Weather Mats, wheel locks, Toyota Silver Tube steps.....
    one question, arent you afraid of that rust doing some damage on the rest of the tailgate??? It could take years, but it could happen....
     
  9. Mar 2, 2010 at 7:59 AM
    #9
    eordonez

    eordonez Living vicariously through mjp2

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    OEM All Weather Mats, wheel locks, Toyota Silver Tube steps.....
    You are right, they redesigned it somewhere on the 2008 production ;)
     
  10. Mar 2, 2010 at 11:04 AM
    #10
    Cars0n`

    Cars0n` [OP] Well-Known Member

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    Edmonton AB
    Vehicle:
    07 2wd access cab base.
    Kenwood DDX-512 Deck, Boston Acoustics G5 Sub in Ported Bassworx Box, Kenwood eXcelon KAC-X10D Amp, Sirius Satellite Radio, Magellan GPS, DDM 55w bi-xenon headlights, 2 HID Hella 500ff's mounted behind grill, 4 pc ebay Billet grill, Fog Lights (my truck didnt have them stock), Pioneer Speakers 6x9's(front) 6.5's(rear) AFE Cold Air Intake, Hose Clamp Mod, Tailgate Strengthen Mod, Removed Gay Mud Flaps, De-Badged, BHLM, 245/45/20 on velocity wheels. VW865a, Extra D Rings In Box, OEM Cruise Added Optima Red Top Battery
    yes, but after im all done im gonna give it a coat or paint, or at least clear (only the inside of course)

    im done all i can do now, just heading up to a friends now so i can weld it all together. ill be back in a few hours and have the final pics up.
     
  11. Mar 3, 2010 at 12:03 PM
    #11
    Cars0n`

    Cars0n` [OP] Well-Known Member

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    Carson
    Edmonton AB
    Vehicle:
    07 2wd access cab base.
    Kenwood DDX-512 Deck, Boston Acoustics G5 Sub in Ported Bassworx Box, Kenwood eXcelon KAC-X10D Amp, Sirius Satellite Radio, Magellan GPS, DDM 55w bi-xenon headlights, 2 HID Hella 500ff's mounted behind grill, 4 pc ebay Billet grill, Fog Lights (my truck didnt have them stock), Pioneer Speakers 6x9's(front) 6.5's(rear) AFE Cold Air Intake, Hose Clamp Mod, Tailgate Strengthen Mod, Removed Gay Mud Flaps, De-Badged, BHLM, 245/45/20 on velocity wheels. VW865a, Extra D Rings In Box, OEM Cruise Added Optima Red Top Battery
    got all the pieces cut and fit right

    [​IMG]


    drilled out the holes for the bolts.

    [​IMG]


    bolted them in

    [​IMG]


    this is all of them in their places

    [​IMG]


    welded each of the pieces together. and did a little coat of clear on the welds

    [​IMG]


    clearing the top where the paint was all cracked.

    then after this step i epoxied all the brackets back down and re assembled.

    [​IMG]

    Tunes setup

    [​IMG]


    tools i used on the bench

    [​IMG]

    mess on the floor

    [​IMG]


    broken drill bits.

    [​IMG]


    and im done. it is noticibly heavier and sturdier. have yet to weight test it yet tho.
     
  12. Apr 15, 2010 at 4:32 PM
    #12
    Tillers_Rule

    Tillers_Rule ......................

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    Carson, that's a good write up and project.

    Would you be interested in making these for sale? Some of us don't have access to the necessary tools to fabricate them.
     
  13. Apr 15, 2010 at 4:39 PM
    #13
    Cars0n`

    Cars0n` [OP] Well-Known Member

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    Vehicle:
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    Kenwood DDX-512 Deck, Boston Acoustics G5 Sub in Ported Bassworx Box, Kenwood eXcelon KAC-X10D Amp, Sirius Satellite Radio, Magellan GPS, DDM 55w bi-xenon headlights, 2 HID Hella 500ff's mounted behind grill, 4 pc ebay Billet grill, Fog Lights (my truck didnt have them stock), Pioneer Speakers 6x9's(front) 6.5's(rear) AFE Cold Air Intake, Hose Clamp Mod, Tailgate Strengthen Mod, Removed Gay Mud Flaps, De-Badged, BHLM, 245/45/20 on velocity wheels. VW865a, Extra D Rings In Box, OEM Cruise Added Optima Red Top Battery

    thanks, but unfortunately seeing as how i am so far out of the way it would be ridiculous for shipping. and im pretty busy with school as it is so as of now no sorry man. im sure if you bring it down to a fab shop and maybe even print this out they could do it for you, and im willing to bet it would be a better job. not sure how much it would cost tho.
     
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