TAILGATE REPAIR - New Front End - Pictures

62 OlllO

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1962
#1
Where does a person start...after looking at my '62 for weeks, I decided to start on the tailgate...besides I could take it off and play with it inside. First I had to drill the screws out that attached it to the body, that was easy...remove the chrome and license plate bracket so I wouldn't damage them while working. I started cutting away the inside rust first and replacing it with good metal. I don't have a break or sheer big enough to do the project in one piece...reason for three pieces.

[attachment=2:3j30zp6u]DSCN1360.jpg[/attachment:3j30zp6u]
[attachment=1:3j30zp6u]DSCN1365.jpg[/attachment:3j30zp6u]
[attachment=0:3j30zp6u]DSCN1366.jpg[/attachment:3j30zp6u]

The rust is nasty, as you can see the rust is on the inside of the tail gate, places you can't see...you can assume that rust on your vehicle is everywhere you can't see...so I spray and brush a phosphoric solution (called ISPHO sold at Ace Hardware). The solution will dry over night and turn rust and shinny new metal dark gray or black...protected and ready for epoxy primer or body putty.
Other than my time, I have nothing into this repair and it took approximately 10-12 hours. The big brown pile is half the rust that came out of the tailgate. The bottom of the tailgate has a piece of angle iron that the screws attach the hinge to...I drilled holes, welded nuts and re-tapped...welding it into place by drilling holes in the new metal by spot welding. Is the repair perfect...no...but I can live with it. I will know more when I wipe body putty...but I have some work left with the TG before mud.
 

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BioTex

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#2
Re: TAILGATE RUST REPAIR

Kevin,
Looks like your getting serious now! :D
You should start a build thread so we can follow along. Having to deal with all that rust is overwhelming to me. Looks like you got the tailgate fixed good. Are you going to have to remove body panels to get to the inner wheel wells?
 

62 OlllO

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#3
Re: TAILGATE RUST REPAIR

Slow down cowboy, un-saddle that horse, come sit for a spell. I've come along way and my thirst is next. I'll have to do something with the quarters, specially the left....who ever put it on...used rivets...both quarters are rusty, but being cheap, I'm looking at cutting and replacing rust instead of buying replacements. I really want to start on my front end conversion...Dana 44's, Steering Box, Lengthen the frame and new springs. So for now, I'm back to "sy-phoring" (looking at it, planning next move, requiring a beer in your hand at times to get the creative juices moving)
[attachment=0:18m7k7yi]DSCN1368.jpg[/attachment:18m7k7yi]
I have plenty to do...
 

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splinterguy

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#4
Re: TAILGATE RUST REPAIR

Kevin,
That looks like a great start to me, keep up the good work. Are you going to be able to use the original hinge? I have a wagon that I am going to need a new/better hinge for as that rust bugs have chewed on it as well as the gate. Glad to see you are warming up to your wagon.
 

73fj

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#5
Re: TAILGATE RUST REPAIR

I "sy-phor" exactly the same way, as a matter of fact sometimes for so long all my "sy-phoring" juice disappears. :lol: :lol:
 

62 OlllO

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#6
Re: TAILGATE RUST REPAIR

Gee wizz fella...I'll bring some Georgia Moonshine and we can all howl at the moon, solving all my problems until morning peaks it's ugly head out....I'm having vendor problems...stay tuned.
 

pavel6

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#7
Re: TAILGATE RUST REPAIR

Nice repair on the tailgate... what's the condition of the rear edge of the floor? I my case, the tailgate hinge had very little holding it to the rear floor, so major reconstructive surgery was required. Take a look if you are interested:
http://www.members.shaw.ca/pavelb/body.html

Cheers

BTW: I replaced the stock hinge with a SS version which I found at a truck parts outlet ($30, if memory serves)

Pavel
 

73fj

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#8
Re: TAILGATE RUST REPAIR

62 OlllO said:
Gee wizz fella...I'll bring some Georgia Moonshine and we can all howl at the moon, solving all my problems until morning peaks it's ugly head out....I'm having vendor problems...stay tuned.
Hey, don't be offended there Kevin, I was just agreeing with you. I like to have a beer while problem solving too.
 

62 OlllO

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#9
Re: TAILGATE RUST REPAIR

Pavel6 thank you for the link and reminder...I have to admit to my reading audience, I have seen your sight and build pictures. And yes, I will be rebuilding the rear edge of the floor too. Previous owner decided to weld the trailer hitch onto the frame and rear bumper. Which made it difficult in removing the gas tank... No gas wrenches until I did that. My hinge is in good shape so I will massage it and install. Only put 4 hours into Wagon today...40 degrees and getting colder....but it was a good, short date with my girl. ;)
 

62 OlllO

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#10
Re: TAILGATE RUST REPAIR

73fj....I wasn't offended at all and I'm sorry my post made you think I was...my humor I guess mis-led you....just being from Georgia, I was offering some fine white lightening to go along with our cold beer...Southern Hospitality.
[attachment=0:bbc5t3t4]DSCN1277.jpg[/attachment:bbc5t3t4]
 

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rcshook696

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#11
Re: TAILGATE RUST REPAIR

Kevin, nice start on the tailgate. I clean in the garage and found my pooltable. Now where to put it. BioTex has the metal cut for my windshield. Hopefully I"ll have the pooltable moved so i can get her in the garage by the time the sheet metal gets here. Kids won't let me get rid of pooltable. Keep up the good pics. Do you have more of what came off of floor to mount hinge to? Mine is missing and I do have a piece to put back there but do not know if it is all that needs to be there. Great work, Chuck.
 

62 OlllO

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#12
Re: TAILGATE RUST REPAIR

Check Pavel6 link in earlier post here...regarding lower floor edge the tailgate hinge bolts to. Regarding the pool table...pulley's and rope - to the ceiling or put it outside with a plastic cover over it...kids can play 12 months of the year.[attachment=1:3kcc18ue]Chessers019.jpg[/attachment:3kcc18ue] [attachment=0:3kcc18ue]Chessers020.jpg[/attachment:3kcc18ue]
 

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73fj

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#13
Re: TAILGATE RUST REPAIR

I'm glad you were not offended, I'm not here to piss anyone off, and sometimes what I think is funny draws blank stares.

My tailgate looks like yours and is going to need the same treatment when I get home, hopefully before xmas, then over the holiday I plan to hit it hard, gotta build a fab table too. Keep at it, looks like good work so far. ( I am intrigued about the moonshine and beer thing )
 

rcshook696

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#14
Re: TAILGATE RUST REPAIR

73fj You can buy a portable work stand from Harbor Freight Tools for $20. I just bought 2 of them on sale for $15. Lay a piece of plywood on it for a table. This stand works great for autobody work where you can access top and bottom. Fold it up when not in use. Item number for the stand is 38778, link is -http://www.harborfreight.com/cpi/ctaf/displayitem.taf?itemnumber=38778&Submit=Go It doesn't say about shipping to Canada but I imagine they will. Just give me themoonshine and i won't care about the beer!
 

62 OlllO

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#15
Re: TAILGATE RUST REPAIR

[attachment=1:14es85tq]DSCN1421.jpg[/attachment:14es85tq]
Getting ready to pull the engine, tranny and transfer case...cut the exhaust off, drained the anti-freeze, cut all wiring. Then I'm going to try to do what Midnightburn did to his beautiful Wagon...with my twist.
[attachment=0:14es85tq]DSCN1424.jpg[/attachment:14es85tq]
Welded little cracks in both fenders, ground smoothly....if the weather would cooperate I'd date this girl more often.
 

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Pete

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#16
Re: TAILGATE RUST REPAIR - THE START OF DATING

Full steam ahead... I'm digg'n your updates.

Pete
 

Imposter71

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#17
Re: TAILGATE RUST REPAIR - THE START OF DATING

looking good. Can't wait to see what is next!!!
 

rcshook696

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#18
Re: TAILGATE RUST REPAIR - THE START OF DATING

Hey Kevin. Getting pooltable out this weekend and rolling the 57 in. I think I'll buy the lower piece for the tailgate from walcks. It's $115. Not as bad as Kaisers. Will post pics as soon as I get started. Chuck
 

BioTex

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#19
Re: TAILGATE RUST REPAIR - THE START OF DATING

Chuck,
You should get the sheet metal I sent you any minute now. I'm sure you will have you hands full installing them. Please take lots of pics to share.
 

62 OlllO

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#20
Re: TAILGATE RUST REPAIR - THE START OF DATING

One of my favorite air tools when replacing metal...it makes a nice crimp that lays nicely behind existing metal and will punch a perfect hole for spot welding....finished product is a nice smooth lap seam requiring less bondo.
[attachment=2:3mxr4946]DSCN1436.jpg[/attachment:3mxr4946]
Finally ready to remove engine...look closely at all those wires....I had plugs wires drooping below the frame. It's a good thing I'm in the rebuilding stage, I have found cracks in vital frame area's, bolts loose, factory rivets missing in steering frame bracket and basic bad workmanship when someone replaced the stock springs.
[attachment=1:3mxr4946]DSCN1437.jpg[/attachment:3mxr4946]
Anyone know anything about a RANCHO after market leaf spring, on all four corners of this Wagon....providing a 2+ lift.
[attachment=0:3mxr4946]DSCN1439.jpg[/attachment:3mxr4946]
Another cold day here in Georgia for working outside....Received my new rear quarter panels yesterday $520.00 delivered...and YES the die being used to make these... is worn out...these quarters loose detail, but it speeds things up when repairing metal around wheel wells. When these quarters are the only game in town you have to play with whats available... Love having them, hate having to use them. After I install them I will prepare the inside with a paint so these won't rust as fast. The rest of the metal work I will be making...everything is expensive. I guess that's why I don't build authentic resto's...I don't have the talent for perfection and money to purchase the NOS parts.
 

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