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What might you ask am I doing with this card board?? Pics.

rdn2blazer

rdn2blazer

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Why Im going to fabricate a custom hard top hatch door, thats what. :D. Since Im running a pickup truck tail gate instead of the heavy crappy K5 gate I need a hatch door to keep the weather and those who steal out. I have a plan allready for how Im going to do is so it should come out pretty good and water tight............hopefully, thats the goal anyways. I went with a 5 inch boarder all the way around. Will keep pics coming as the progress continues.

DSCN2271.JPG

DSCN2272.JPG

DSCN2273.JPG
 
how did you get the pickup tailgate to seal to k5 tub? i want to do this, but can't have water pouring in! i have a 1st gen also, and wonder if the same bottom and side seals and the piece of angle iron bolted on top of tailgate for the hatch door would work on my 2nd gen w/ pu tailgate?
 
What about cutting up 2 suburban barn doors and welding them together or using them seperatly.
I do like the fibergall i dea though looks like a cool project definatly subcribed
 
bp71k5 said:
You'll need a lot of RTV to make that cardboard watertight. ;)
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LOL!! Im going to be using 1/8 sheet Aluminum. Going to use Lexan as the window and sandwhich the Lexan between the two pieces of Aluminum. I will seal the window with trim to keep it water tight. I think I will use stainless Steel rivets around the window to help locate the window and rivet around the perifery of the frame itself. Then I will edge trim the frame so when it closes against the top and tail gate hopefully it seals. I'll get a top strut thingy to assist lifting it and to hold it open.

IF it feels too flimsy which I dont think it will I will rivet in some stiffiners to stiffen it up. I will have two or three Stainless steel hinges on the top and some kind of lock latches to the tail gate. It may not look all that pretty but I dont care about that as long as it works and is not so easy to break into. I might even french a lock into the tail gate.
 
blazin_blazer said:
how did you get the pickup tailgate to seal to k5 tub? i want to do this, but can't have water pouring in! i have a 1st gen also, and wonder if the same bottom and side seals and the piece of angle iron bolted on top of tailgate for the hatch door would work on my 2nd gen w/ pu tailgate?
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I hav'nt crossed that bridge yet, Weather trim of some kind I suppose..
 
mnstrburbon said:
What about cutting up 2 suburban barn doors and welding them together or using them seperatly.
I do like the fibergall i dea though looks like a cool project definatly subcribed
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Thats doable too but to me it sounds like more work. I think this will be kinda trick. I will probably have the Aluminum sheets powder coated when im done.
 
Does anyone have any suggestions that might be a better choice for a window over Lexan? Anyone know about Polycarbonate? (spelling?)
 
What about using a pickup truck rear window? And somehow mounting that in your piece of aluminum?
 
I think Lexan is just a brand name for polycarbonate. Acrylic (plexiglass) is similar and it polishes out better than PC, since it's softer. If you have a TAP plastics store out there, try them. Nothing is as good as real glass in the weather.
 
muddermilitia said:
If you want some measurements, let me know. I have an extra back window.
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Thanks man, the opening in my mock up is deffinitely much smaller then a rear window. Im going to price aluminum tomorrow, Got to save my pennies cant afford that right now.
,
 
Rear window in my blazer is Poly carbonate. So far so good. Never taken a hit either.
 
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