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Tailgate Rebuild

From 1991 Ford Bronco “The "BBB"”, documented by Jacque Strap.

11 photos
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1991 Ford Bronco - This is after the rusty bottom half was cut away. I had already sand-blasted the inside of the shell, then coated the inside with primer an… 1991 Ford Bronco - Since this was only to be a short-term repair job, I made my own brackets for the torsion bar. (at the time I was new to welding and it's o… 1991 Ford Bronco - If you ever decide to do this, don't cut off the bottom - inside bracket, it makes everything a lot easier to line up. Notice the rust. The… 1991 Ford Bronco - I used weld thru primer for my welds, I also left a great deal of old metal under the new skin to help line it up.(BTW, I find weld thru pr… 1991 Ford Bronco - The new panel welded in place. (remember scrap off that so called black primer that comes on all new panels.) 1991 Ford Bronco - This is a view from the bottom, and yes I did put lots of drainage holes in afterwards. 1991 Ford Bronco - I made 3 pieces to go along the bottom. I used tools in a machine shop to make them perfect. 1991 Ford Bronco - Tailgate all primed. This was actually before the new panel was put on. (I only got red primer because it was on sale, gray is easier to co… 1991 Ford Bronco - This is the final product all painted. I used spray cans that were mixed from the paint code at a local automotive paint shop. 1991 Ford Bronco - Another shot of the finished tailgate. 1991 Ford Bronco - Back on the truck. The trim covers up the weld and the paint match is near perfect.