Build Thread - Burb Barn Door to Tail Gate Conversion

[Daveo91Burb]

Well, I've finally made some progress on the project. I've decided that instead of replacing the entire rear cross member/tail gate support, I'm going to modify the existing cross member. This involves two operations: 1) reinforcing the areas where the tailgate hinges bolt up and 2) cutting out part of the existing sill plate and then mating the tailgate sill plate in its place. This is necessary since the tailgate sill plate has a large concave fillet to allow clearance for the gate. It also has rectangular holes for the hinges. Take a look at my album so far - it should explain what I'm doing for both. This weekend hoping to get the tailgate primed. I'll add more pics as I do the work! Advice and suggestions welcome! Thanks.

https://goo.gl/photos/fR1NWYPoRBRuqAKh6

 

[Daveo91Burb]

Any input on this project? Any pitfalls I'm not seeing? I'll post a few pics from recent progress below - I know not everyone likes clicking links.

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[foamypirate]

Looking good so far, though I can't help with any tips/advice. I never knew there was such a huge different between the two, guess it never crossed my mind. Cool little project though!

 

[yevgenievich]

the only tip i have is make sure there is a seal between the upper frame surround and the body, otherwise water will flow inside during rain with no restrictions.

 

[bucket]

I think you're doing a fine job

 

[Daveo91Burb]

the only tip i have is make sure there is a seal between the upper frame surround and the body, otherwise water will flow inside during rain with no restrictions.

Thanks, all! I saw your recent post about water intrusion around the upper frame. Definitely plan to take care of that - the original foam-type seals on the back of those pieces were hard and completely useless. I've since removed all the old material. What type of material did you use there?


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[Daveo91Burb]

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Got all the pieces primed tonight. Paint tomorrow. Got to try out my new $10 HF HVLP paint gun tonight - works awesome. Best $10 I ever spent


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[yevgenievich]

Thanks, all! I saw your recent post about water intrusion around the upper frame. Definitely plan to take care of that - the original foam-type seals on the back of those pieces were hard and completely useless. I've since removed all the old material. What type of material did you use there?


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I ended up just putting a thick bead of silicone and made sure to seal at the joint seams of the seperate pieces. There might be repro seals available, but i needed it back together quickly.

 

[Daveo91Burb]

Great, thanks. I think I'll do something similar.


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[Daveo91Burb]

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Got some paint on there tonight!


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[Daveo91Burb]

Well, I'm not quite to the point of no return on this project, but I'm close. Barn doors are off, as are all the other attachments that go around the opening, including the electrical contact plates that were riveted on. Got all that done and also made a good start on the wiring. Unfortunately I discovered that I have to reroute the rear defroster wiring. On the tailgate burbs in came in from the bottom, but on the barn door ones it came in through the top. Just another small task in a list of many!

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[Daveo91Burb]

Made some good progress the last couple of weeks. Definitely well past the point of no return now!

- Cut off most of the original tailpan/sill plate
- Installed and welded in tailgate tailpan.
- Done most of the wiring (switch on dash, plus I'm adding a switch in the back so if sleeping back there can roll down window without going up front; also had to reroute defroster wiring)
- Installed the three upper trim pieces
- Painted the lower jam
- I have pics of most here, more detail in my album link at the top of thread.

Main technical challenge remaining: how to mount gate latch pin (square hole with backing nut) and cable support pin. Latch pin I will probably just use the threaded backing plate but not sure about the cable support pin. Ideas??

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[yevgenievich]

Rivnut was discussed in one of the other threads.

 

[Daveo91Burb]

Thanks, definitely could be an option. I don't know much about them, though. I see Amazon has them, but where do you buy them locally? Hardware Store? Can you rent the installation tool somewhere?

My other idea is to cut out the part from the original that has the threaded backer (I think it's welded on to the sheet metal?) and then cut out a hole for the recessed part in mine and sheet metal screw the plate with backer on in the proper location. Definitely not as clean as a rivnut though.

 

[The88]

Check Harbor Freight or Northern Tool. They usually have anything you may need.