Well here is my write up for my cheap drop down tailgate mod on my 2000 Jeep Wrangler.
It only cost me $50 and 1 trip to Homedepot, and about 1 hr to install.
Parts and supplies needed:
2 strong door hinges, I chose smaller 3 1/2in black ones with rounded corners.
1 Box of 1/2in self taping metal screws, screw head of your choice, I had hex heads so that's what I used.
About 6ft of 1/8in wire, again you choose the gauge and coating. I chose a thin 1/8in wire rated for 340lbs that is coated in a clear plastic.
4 3/16" Clamp set. (1 loop for each end of wire.)
2 mini D rings (1/4in Anchor fasteners, you can use any type of strong quick release fastener.)
4 1/4in anchor shackles.
T40 star bit for the tail gate bolts on the Jeep.
Time for install and prep
: Before starting spray some PB blaster or something to loosen up those factory tailgate hinge bolts. It sucks hard when those strip.
OK, before you begin unbolting the tail gate from the Jeep measure out evenly where you want the hinges to go on and then drill/screw them in. I personally kinda eye balled mine and and marked them at what turned out to be close to 8in in from the outside of the tailgate. http://s71.photobucket.com/user/Trai...tml?sort=4&o=0
Once the new hinges are installed, go ahead and remove the old ones and drop the tail gate. Make sure it opens and closes smoothly. Mine kinda catches for a brief moment. http://s71.photobucket.com/user/Trai...tml?sort=4&o=4
Time to measure out where you want those anchor shackles to go. If you look at the image above you see the black plate that covers the latch mechanism. Before I screwed into it, I took it off to make sure I wasn't going to hit something important. There was plenty of room where i measured it out so I screwed it in about 3in into the inside of the tailgate on that black plate. I then just did the same thing on the other side. measured out the same length then screwed the anchor in.
For inside the trunk I just eyeballed it and decided to put it in this location, about 6 inches in from the tail gate and 7ish inches up from the floor. Giving it some good angle and strength. http://s71.photobucket.com/user/Trai...tml?sort=6&o=7
Now clamp/secure and attach one end of the wire to the anchor on the jeep and then measure out the wire length and fasten it to either the releasable (d ring) or the anchor on the tailgate. remember they wont be the same length on each side so don't pre cut until you are sure. MAKE SURE ITS LEVEL!
Once those are all secure you should be done! Thanks for checking this out I hope you get good use out of it. My setup holds like just under 200lbs at the moment, I am going to weld the anchor points in and that should give me some extra strength.
ENJOY and thanks for reading! -TrailHunter Ben