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-   -   $30 TJ Fold Down Tailgate (and stuck torx bolt removal) (http://www.jeepforum.com/forum/f37/30-tj-fold-down-tailgate-stuck-torx-bolt-removal-1076528/)

NalinMFG 07-25-2010 08:38 PM

$30 TJ Fold Down Tailgate (and stuck torx bolt removal)
 
https://scontent-a.xx.fbcdn.net/hpho..._1818398_n.jpg




(18) self tapping #14 3/4" sheet metal screws
(2) self tapping #14 1" sheet metals screws
(1) 5/16" nut and bolt
(2) 1/2" nuts
(4) 1/2" washers
(2) 1/2" 1.5" bolts
(2) fence hinges
(2) 90 silverado tailgate cables (or whatever else...i used 15" ones)
(1) little piece of angle iron (i used 3" of 1.5"x1/4")

i had some hardware laying around, but this should be around a $30 mod.

https://scontent-b.xx.fbcdn.net/hpho..._4101381_n.jpg
stuck torx bolts huh?

https://scontent-b.xx.fbcdn.net/hpho..._6891803_n.jpg
clean the surface of the bolt of with a drill bit

https://fbcdn-sphotos-a-a.akamaihd.n..._7646577_n.jpg
weld on an "L" that you can stick a cheater bar onto

https://scontent-a.xx.fbcdn.net/hpho..._7293977_n.jpg
break that sucker free:highfive:

https://scontent-b.xx.fbcdn.net/hpho..._6167136_n.jpg
factory hinges off tailgate

https://fbcdn-sphotos-c-a.akamaihd.n..._7911702_n.jpg
used tab as a spacer to keep both sides level

https://scontent-a.xx.fbcdn.net/hpho..._1767414_n.jpg
pilot hole for center bolt on hinge (i came in 4" from the outsides)

https://scontent-b.xx.fbcdn.net/hpho..._2010170_n.jpg
hinges on

https://fbcdn-sphotos-f-a.akamaihd.n..._3394984_n.jpg
hinges completely on

https://scontent-b.xx.fbcdn.net/hpho...6_958403_n.jpg
made a piece angle with holes for the passenger side

https://fbcdn-sphotos-f-a.akamaihd.n..._8269947_n.jpg

tested 360lbs without problem (my dad and I). :thumbsup:

ajamison 07-25-2010 08:42 PM

great write up! i was just thinking about doing my tailgate today, but the local hardware store is closed on sundays.. i think ill take your parts list to the hardware store this week and get to work :thumbsup:

Fropleyqk 07-25-2010 10:59 PM

very cool :thumbsup:

2006_Sport 07-26-2010 01:14 AM

What'd you do about the spots where the hinges used to be?

NalinMFG 07-26-2010 08:54 AM

Quote:

Originally Posted by 2006_Sport (Post 9851213)
What'd you do about the spots where the hinges used to be?

im going to laser cut some pates to go over them. now that all the holes are drilled ill use stainless countersunk hardware to match the rest of the armor.

mountaineerjp 07-26-2010 09:10 AM

Do you have any more pics of the bumper/cross-member setup? I am very close to doing something like that and I am interested in how you incorporated the receiver.

InfernoGirl 07-26-2010 09:25 AM

Looks great! You do such nice work :)

DanZ51 07-26-2010 10:04 AM

Pretty Damn good for a Cannon Co(ker :thumbsup:

NalinMFG 07-26-2010 10:39 AM

Quote:

Originally Posted by mountaineerjp (Post 9852090)
Do you have any more pics of the bumper/cross-member setup? I am very close to doing something like that and I am interested in how you incorporated the receiver.

its pretty much just genrights crossmember kit...just wth d ring tabs welded on and a 2" id reciever cut into the center.
Rear Tire Carrier

i wouldnt recoment towing with it. its really only 3/16" + the factory stamped corssmember. its only one mine incase i need to center pull someone out

NalinMFG 07-26-2010 10:41 AM

Quote:

Originally Posted by DanZ51 (Post 9852344)
Pretty Damn good for a Cannon Co(ker :thumbsup:

pull cables off tailgate, tailgate go boom:D

krahnilogikal 07-26-2010 01:05 PM

I don't see any latch mechanism on the top passenger side of the tailgate. How is it on rattles? Seems like with the latch only on one side that it would be loose.

NalinMFG 07-26-2010 01:45 PM

Quote:

Originally Posted by krahnilogikal (Post 9853384)
I don't see any latch mechanism on the top passenger side of the tailgate. How is it on rattles? Seems like with the latch only on one side that it would be loose.

it's very secure and does not rattle, there are 3 or 4 other diy fold down tailgate's online that do not have a second latch either

NalinMFG 07-26-2010 02:19 PM

Swagoffroad.com YJ, TJ & JK Fold Down Tailgate Conversion Kits

$180+ship for the same thing + a side latch

AustinTexasXJ 07-26-2010 02:28 PM

you think you can use the old hinges for a swing away tire carrier?

Sgt.Fuzz 07-26-2010 02:29 PM

Quote:

Originally Posted by tigertrack1600m (Post 9853807)
Swagoffroad.com YJ, TJ & JK Fold Down Tailgate Conversion Kits

$180+ship for the same thing + a side latch

Yes Swag is sweet, but a $30.00 dropdown tailgate mod that supports 360 lbs. is a very viable option for those on a limited budget. Great job!:thumbsup:


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