86'' Tail Gate

[dennisS1]

Mate of mine, yes I do have some, is tidying up his 86", thus a few panels need replacing.
The Tail gate was a bit on the rough side.
https://www.aulro.com/afvb/images/imported/2014/02/539.jpg (http://s212.photobucket.com/user/dennis1948/media/DSCN0646800x401_zps4fdf3d79.jpg.html)
https://www.aulro.com/afvb/images/imported/2014/02/540.jpg (http://s212.photobucket.com/user/dennis1948/media/DSCN0648800x576_zpsc1b4a7fb.jpg.html)

First job remove all bits to flatten out as pattern and recover the nuts and rope hooks.
https://www.aulro.com/afvb/images/imported/2014/02/541.jpg (http://s212.photobucket.com/user/dennis1948/media/DSCN0650800x600_zps988d7a61.jpg.html)

Fold up new tray.

https://www.aulro.com/afvb/images/imported/2014/02/542.jpg (http://s212.photobucket.com/user/dennis1948/media/DSCN0654800x600_zps917417a8.jpg.html)

Fold and fit support bits that run around tray.
https://www.aulro.com/afvb/images/imported/2014/02/543.jpg (http://s212.photobucket.com/user/dennis1948/media/DSCN0658800x424_zpsdd6a85bf.jpg.html)

Spot weld it all together.
https://www.aulro.com/afvb/images/imported/2014/02/544.jpg (http://s212.photobucket.com/user/dennis1948/media/DSCN0662800x600_zpsc366bfac.jpg.html)

https://www.aulro.com/afvb/images/imported/2014/02/545.jpg (http://s212.photobucket.com/user/dennis1948/media/DSCN0667800x600_zps1c20b2f0.jpg.html)

https://www.aulro.com/afvb/images/imported/2014/02/546.jpg (http://s212.photobucket.com/user/dennis1948/media/DSCN0669800x600_zps29427b85.jpg.html)
Ready for a fine rub and prime, pant and refit some nice gal bits.

[Defender Mike]

I wish there was a spot welder here in Perth my tailgate is ready to go but cant get anyone to weld it.
Mike

[wrinklearthur]

I wish there was a spot welder here in Perth my tailgate is ready to go but cant get anyone to weld it.
Mike

Here you go Mike.

http://www.youtube.com/watch?feature=player_detailpage&v=vrlvqib94xQ

A word of warning, when stripping a micro wave down for parts, watch out for the capacitors as they can store a lethal charge for a long period of time

The tip for the day is that tips can be made from soldering iron tips.
.

[dennisS1]

This is a disclaimer, I am in no way associated with the last post.
Looks like a good way to end up dead or burnt to me.
Plus my microwave is too small to fit tail gates in.
Dennis

[harry]

Nice job Dennis, got all the good toys, nice folder, clecos, looks like you have the sheety bit sorted out.

[wrinklearthur]

Here you go Mike.
Try this eBay one.
Ref; Brand NEW Portable 240V Spot Welder 2 Welding TIP Sets 2mm 5mm | eBay (http://www.ebay.com.au/itm/BRAND-NEW-Portable-240V-Spot-Welder-2-Welding-Tip-Sets-2mm-5mm-/201039654575?pt=AU_Welding&hash=item2ecee5aeaf&_uhb=1)

https://www.aulro.com/afvb/images/imported/2014/02/299.jpg

To spot weld aluminum you need to place a couple of strip's of steel plate between the aluminum and the tip's to stop the tip's sticking.

Here is a YouTube link to a tutorial.
Metal Shaping with Lazze: Spot Weld Aluminum with a 220V Welder - YouTube
.

[ashhhhh]

Wow that's great!