Tailgate Support Replacement - First New Part Installed

[ZombieK5]

The day I dreaded since I Decided to refurbish the K5 came. I had to replace the tailgate support FIRST before the donor Quarter Panels are installed. The existing TG support was horribly corroded (as many are).

There really wasn't much out there for replacing this support. Found a YouTube video where the TG Support was cut into two pieces then installed. I really didn't want to do that and since the Qtr Panels are being removed I went with cutting out the old one. The upright supports had some tight inside corners which created potential problems with my angle grinder/cutter. Went with cutting the external body skin around the taillights first. I then cut most of the corners areas from outside the vehicle. Kept those parts because you never know when you'll need them.

The body mount bolts were shot. Only one had a nut on the bolt. Both were swollen by corrosion. Had to cut off the bolt heads and get out Big Nasty to punch the bolts downward. After a good fight, the bolts lost and Big Nasty was awarded another gold medal. So far Big Nasty is undefeated. Big Nasty is the shit!!!! (Astro 4980 air hammer).

Cut the bed panel and after a few tugs the old TG support came out. I first placed a series of wood boards between the frame and underside of the bed to support the bed once the TG support was removed. I got some minor sagging but I can't tell if it actually sagged or if the old support had issues to begin with.

New TG support went in with some minimal tweeking. It is just sitting there now. I haven't bolted it down yet. Everything seems to be fine....

Any comments, thoughts or suggestions?

 

[Gentleman Jimmy]

Looks like a good start.

Advice...Keep the top and on as you go (if you can) to help keep the bedsides from moving. Make sure the tail pan is squared up and body mount holes align. Tack it up and make sure your tailgate fits properly then burn it in and bolt it down.

comments...looks like there’s a body lift? Are you keeping that? Might be a good time for new body mount bushings while you’ve got it apart.

 

[ZombieK5]

Looks like a good start.

Advice...Keep the top and on as you go (if you can) to help keep the bedsides from moving. Make sure the tail pan is squared up and body mount holes align. Tack it up and make sure your tailgate fits properly then burn it in and bolt it down.

comments...looks like there’s a body lift? Are you keeping that? Might be a good time for new body mount bushings while you’ve got it apart.

I plan on trying to square it up as much as possible. The new quarter panels should provide the correct dimensions down the side when they are installed. The body mount bushings will be replaced at a later date. The roll cage is welded to the frame so I can't do that yet.

My primary concern at the moment is getting the tailgate support installed correctly and getting the quarter panels mounted to it.

 

[formercruiserhead]

You dont have to cut it in half. There are several tabs that help locate and bolt in the new crossmember. Disconnect the body mounts, leave the 2 under the front floorboards in but loose so the body doesn't slide off, jack up the body and support with blocks. Put the new body crossmember in from the bottom and bolt up at tab points. I did plug welds where the floor contacted the crossmember.

 

[ZombieK5]

You dont have to cut it in half. There are several tabs that help locate and bolt in the new crossmember. Disconnect the body mounts, leave the 2 under the front floorboards in but loose so the body doesn't slide off, jack up the body and support with blocks. Put the new body crossmember in from the bottom and bolt up at tab points. I did plug welds where the floor contacted the crossmember.

That would be the perfect solution if the qtr panels were not being replaced, which mine are. Also my roll cage is bolted thru the body into the frame and I can't lift the body upward w/o cutting the roll cage. So... I was kinda screwed. Now that the tailgate support is "loosely" installed I can put in the qtr panels and work them around for proper fit.... At least I hope

 

[Blue85]

If you are replacing the posts, the backing plates and the quarter panels then maybe you can save some time leaving all 3 welded together and cut. You have a spot weld cutter, right? If the quarter panels are aftermarket, I wouldn't count on them for alignment. More like force them to fit.

Here's my thread. I think there's another one in the Body Shop.
https://ck5.com/forums/threads/repa...lacing-the-tailpan-and-floor-patching.333499/

 

[ZombieK5]

Qtr panels are donor from an 85K5

Posts and backing plates are from LMC and will weld them into place before putting qtr panels onto the vehicle. About 2 weeks from that happening. I have some
rust repair to do on the qtr panels 1st.

Here is my build.

77 Blazer - The Beast build

ZombieK5 submitted a new Build: 77 Blazer - The Beast build Read more about this build here...

ck5.com

I have detailed the disassembly of the donor qtr panels. The LMC posts and backing plates seem to fit good. Need to weld them into place. Wish I had the wood contour wooden panel you made... But I should make do

 

[Blue85]

Are you running K5 tailgate or truck gate? I just bring it up because the replacement parts don't have mounting provisions for K5 gate. You'd want to add them before install.

 

[ZombieK5]

K5 tailgate. I plan to add the needed provisions to the tailgate post