Tailgate skin

[Dirk D]

I want to make a tailgate skin for my 01 chevy silverado, because i was recently hit and i want to shave the handle.So i can kill to brids with one stone. On this tailgate , it seems as if the inner and outer skin is one, and the sides and welded , flanged to it.
My plan is to cut the old skin just below the top on the inside, then lap the new over the inside panel and rosette welding them together. The problem lies in making the new skin hemming over the sides and bottom, as the tailgate edge curves and has a large bodyline running through it.
The actual fabrication of the skin will not be the problem, I just don't know how to make the edges hem over the inner and getting it tight. I am wondering if it would be easier to weld the outer to the inner , as in an edge weld, but to me the edge wouldn't be as rounded and would be the cheap way out.
My idea to get the hem started is use 2x4 and create a hammer form for the sides bending a 90, as the bottom can be done in the press brake. But what from there.
Thanks ,
Dirk

[anders nørgaard]

Hi Dirk,

Think I can help you on that one

When you have got the flange tipped/bent/hammered to 90 degrees on all the edges, you install the panel to the inner structure.


To hem the edges, you'll use vise grips or spring clamps to hold the inner and outer panels together along the edges (use a small patch of sheet metal on the outside skin to prevent marking)

Hold a dolly against the outside skin and hammer the edge down/in. Don't hammer the edge entirely down in one spot, but move along the edge and hammer in little by little. Be sure to hold the dolly tight against the outer skin

If the skin has tight radiused corners you have to cut the flange more narrow in these areas, not to have to deal with to much excess material. It's easier to bend a 5/16" flange than a 5/8 8)

After having closed the entire hem, you may have to make a few spotwelds to lock the inner and outer panel together. Make thoses welds on the inside

Remember to apply body sealer to keep water out

Anders DK

[Dirk D]

Well i made the tailgate skin, but there are some things I do not like and will need to be remade. I used my Lennox (pullmax) to do the bodyline, and the rest of the curvature in the panel. The problem is the dies left break lines in the smooth radius of the tailgate (see photo), so I figured out the dies have to be extremely accurate to keep from doing this. So instead of spending all week making dies, I think there has to be an easier way.

Maybe by forming the bodyline in the dies, then form the hem edge by bending the 90. Take the panel over to the shrinker and shrink the hem edge(on both ends of the tailskin) to create the curvature.
The only problem i am having is creating the hem edge, as you can see by the template, the body line is compact and rigid. I think maybe creating a hammer form and hammering the hem over the form? I don't think a bead roller with tipping dies will be able to form the hem on the bodyline.