Tailpan, tailgate hinge repair.

[nwcustoms]

Hello all, this my first thread so bear with me and mistakes. I have a 91 k5 with rust issues in both back corners. This thread is about my attempt to repair it using the tech article on this site as a reference. I will try to post as many pics as possible. So, here goes!!

 

[nwcustoms]

After removing bumper this is what i found, then i started tapping with a welding hammer to find all the rot.

 

[nwcustoms]

Next step, measure, measure, measure, then i cut the floor, 2 inches back, just the floor, not the tail pan underneath! Also highly recommend a spot weld cutter for the First row of spot welds. (I got mine from eastwood. ). You will have to cut through spot welds to get floor off rear tail pan.

 

[nwcustoms]

Next remove the back and top of tail pan. NOTE. On the top of pan only cut 1 1/2" from back of pan. I cut 2 inches as stated in article, but i think for my repair 2" is too much. Also VERY IMPORTANT! SAVE as much of lower pan support as possible.

 

[nwcustoms]

Lower pan support

 

[nwcustoms]

This is what it looks like now, and with my 2"x2" test fitted. I had to tap the lower pan support down to get the piece to slide into place.

 

[nwcustoms]

Will try to get to more this weekend, next step, removing the rest of the rust and replacing the bottom of the bed uprights on both sides. People talk about removing the bolts on either side of tailpan to remove it, my bolts and mounting surfaces are totally gone!!!

 

[Deuling]

Nice work!

I shall watch.

Hey Brian, you better pay close attention

 

[nwcustoms]

Got the bed support sectioned, and mocked up my outside 2"x3" piece. Thinking about just going 2"x3" all the way across.

 

[nwcustoms]

Went with 2"x3" all the way, across

 

[nwcustoms]

Got filler pieces installed to replace the part of tailpan that was gone, side note, bed did settle 1/8" on both sides so i had to jack up body to get the 2"x3" in

 

[919jackass]

this is awesome i may need to do mine had it up on the lift today and saw it. ****! mines not bad bad yet but i know its only going to get worse

 

[nwcustoms]

Hey guys, need a little help, i missed a measurement. Can somebody measure from center of rear body mount bolt to the rear edge of tailpan? Thanks for any help. Mine is a 1991.

 

[Deuling]

I don't have mine in town unfortunately, but I will bump it to the top for ya

 

[76zimmer]

Hey guys, need a little help, i missed a measurement. Can somebody measure from center of rear body mount bolt to the rear edge of tailpan? Thanks for any help. Mine is a 1991.

Maybe you could hold the tailgate up there in the closed position, and allow 1/4" gap between the floor and tailgate?

 

[919jackass]

next set of body mounts up close to the center of the rear wheel wells is 42 7/8 but that is from the rear edge of the circle. yeah i was standing at the tailgate. just undercoated the inside. if you need from center let me know i can do it tomorrow

 

[nwcustoms]

Ya ok thanks, but i was wondering if you could get from the rear most body bolts. Maybe a few inches from end of the bed. My body bolts between wheel wells have been modified by previous owner, maybe moved, really appreciate the help. Thanks

 

[swettysblazer]

I'll be watching this, doing mine soon.

 

[British Slave]

Hey guys, need a little help, i missed a measurement. Can somebody measure from center of rear body mount bolt to the rear edge of tailpan? Thanks for any help. Mine is a 1991.

My 87 is exactly 4 inches. Hope that helps.

 

[919jackass]

o **** mine is an 88 k20 and im 1 3/8 inches. well i hope these help you if you want measurement from wheel wells of anything else let us know. i figured they were all the same.