Reinforcing the Jeep's Tailgate

Tejas@perioimpl · 12th May 2010, 16:01

It was bound to happen sooner or later. My Classic's tail gate has started drooping and it takes atleast 4-5 attempts to shut it properly. The added weight of the spare tyre has compounded the problem.

What to do about it?

I don't want to seal the door (some people have suggested it to me earlier).

I will be adding a luggage rack in the near future to carry an ice box and jerry can. Thus, the door hinges need even more reinforcement.

How to go about this? Can anyone give exact details so i can get the hinges reinforced by my local mechanic.

I don't want to go in for a custom bumper with integrated tyre rack, etc.

Jaggu · 12th May 2010, 16:09

Why don't you put in new hinge and fix the tail gate. Then get a used spare tyre frame and fix it so that the weight is isolated from the gate. Its not a difficult job and is not costly also. Or remove the spare and put it inside on the floor, icebox etc can sit on top of it.

Alternative find a heavy duty hinge, you have the contacts in spare shop so shop around. And try to add a sturdier lock system on the opening side to take the weight off, you can mount it inside if the available options are fugly.

Best is to add the spare frame, since it will soon take the toll on the actual gate or the existing clamp etc ie assuming new tires are real heavy in comparison.

Just curious how much of weight diff between old and new tires? shouldnt be more than a kilo right?

ex670c · 12th May 2010, 16:09

Quote:

Originally Posted by Tejas@perioimpl

It was bound to happen sooner or later. My Classic's tail gate has started drooping and it takes atleast 4-5 attempts to shut it properly. The added weight of the spare tyre has compounded the problem.

What to do about it?

I don't want to seal the door (some people have suggested it to me earlier).

I will be adding a luggage rack in the near future to carry an ice box and jerry can. Thus, the door hinges need even more reinforcement.

How to go about this? Can anyone give exact details so i can get the hinges reinforced by my local mechanic.

I don't want to go in for a custom bumper with integrated tyre rack, etc.

MAN!!!!!

Give it a Break!!!! Now you want a MM550XD Tail Gate

Check the M&M Major or the post 2002 MM550XD Tailgate and Swing Away Tire Carrier.

Regards,

Arka

PS - Just Bolt the Tail Gate and let it be, don't spoil the orignality, besides there is a lot of scientific reasoning and engineering.....

motocamp · 13th May 2010, 07:17

Quote:

Originally Posted by Tejas@perioimpl

It was bound to happen sooner or later. My Classic's tail gate has started drooping and it takes atleast 4-5 attempts to shut it properly. The added weight of the spare tyre has compounded the problem.

What to do about it?

I don't want to seal the door (some people have suggested it to me earlier).

I will be adding a luggage rack in the near future to carry an ice box and jerry can. Thus, the door hinges need even more reinforcement.

How to go about this? Can anyone give exact details so i can get the hinges reinforced by my local mechanic.

I don't want to go in for a custom bumper with integrated tyre rack, etc.

Hey tejas I have just got my prototype tailgate yesterday.

If you want your tailgate to work and not rattle or wobble forget about the mahindra tailgate....you can reinforce it any which way it can only improve the problem a little.

I know i have done it a number of ways, after a few otr's you will be back to square one.

I will post pictures of my tailgate a little later in the day(it is incomplete and in the rough stages)

It Is bolted to the chassis via a 4mm thick rectangular tube bolted at 6 points via 10mm bolts, the tailgate hinge uses ball bearings around a 25mm hardened pin.

The tailgatee locking mechanisim,tyre bolting flange and the support bracket for the tailgate when closed is pending but next otr you can have look at the finished product.

arjunrudra · 13th May 2010, 07:22

Can't the Jeeps Tailgate be shut permanently. Mine is closed permanently as I was told the tailgate was to give sure shot problems with the chassis bending while offroading.

motocamp · 13th May 2010, 08:12

Quote:

Originally Posted by arjunrudra

Can't the Jeeps Tailgate be shut permanently. Mine is closed permanently as I was told the tailgate was to give sure shot problems with the chassis bending while offroading.

Shutting the rear tailgate permanently is the easy way around the problem and works....but for guys like me who carry a lot of stuff ,getting heavy stuff in and out of the jeep on an otr and otherwise would be a hurculean task with a fixed tailgate.

You mean the body, the jeep chassis would not flex enough to disrupt a tailgate fixed on the rear cross member.

Besides i am prepping Alfa Kilos jeep for something special...

Tejas@perioimpl · 13th May 2010, 11:32

Motocamp,

I'll check out your tailgate idea when we meet for the next recce.

Arkaji,

Thanks for the phone discussion. Will work on the gate rubbers this weekend and update.

AVR · 13th May 2010, 14:33

Quote:

Originally Posted by Tejas@perioimpl

Arkaji,

Thanks for the phone discussion. Will work on the gate rubbers this weekend and update.

@Tejas,

Please update this thread based on what you guys discussed. 2 days of regular usage and its bugging me. Want to solve this problem right away.

Cheers,
Adi

Tejas@perioimpl · 13th May 2010, 14:37

Quote:

Originally Posted by AVR

@Tejas,

Please update this thread based on what you guys discussed. 2 days of regular usage and its bugging me. Want to solve this problem right away.

Cheers,
Adi

I'll update as soon as i do what is suggested with WIP pictures.

motocamp · 13th May 2010, 14:58

This is what the tailgate i have designed looks like now remember it is incomplete still in the design stage.

But you can see it is strong ....with ram standing on it you can easily swing it shut due to the bearings around the pin and it does not wobble or sag.

Tejas@perioimpl · 14th May 2010, 12:34

Kunal, how do you lock/secure the tailgate?

AVR · 14th May 2010, 13:00

Quote:

Originally Posted by Tejas@perioimpl

Kunal, how do you lock/secure the tailgate?

Yes. And how do we ensure that the new tailgate that you make won't make the same type of rattling sound? And if there's a way of solving this problem with the new tailgate, why can't we just solve it with the existing tailgate! Am a bit confused now.

Adi

jeepster · 14th May 2010, 13:02

hi motocamp
the tail gate looks a little inclined.

Reinforcing the Jeep's Tailgate-dsc_0580.jpg

motocamp · 14th May 2010, 14:16

Quote:

Originally Posted by Tejas@perioimpl

Kunal, how do you lock/secure the tailgate?

The Tailgate will stop and rest on top of a adjustable block bolted to the rear fender while it is shut and will be secured with a clamp type lock.

V-16 · 14th May 2010, 14:21

That looks like a great solution Kunal. If you guys had a CJ you would not be facing this problem

...or have i spoken too soon?

12th May 2010, 16:01	#1
Tejas@perioimpl Distinguished - BHPian Join Date: Sep 2008 Location: Bombay Posts: 4,423 Thanked: 9,581 Times View My Garage	Reinforcing the Jeep's Tailgate It was bound to happen sooner or later. My Classic's tail gate has started drooping and it takes atleast 4-5 attempts to shut it properly. The added weight of the spare tyre has compounded the problem. What to do about it? I don't want to seal the door (some people have suggested it to me earlier). I will be adding a luggage rack in the near future to carry an ice box and jerry can. Thus, the door hinges need even more reinforcement. How to go about this? Can anyone give exact details so i can get the hinges reinforced by my local mechanic. I don't want to go in for a custom bumper with integrated tyre rack, etc.
	() Thanks

12th May 2010, 16:09	#2
Jaggu Team-BHP Support Join Date: May 2004 Location: Bangalore Posts: 20,215 Thanked: 15,906 Times	Why don't you put in new hinge and fix the tail gate. Then get a used spare tyre frame and fix it so that the weight is isolated from the gate. Its not a difficult job and is not costly also. Or remove the spare and put it inside on the floor, icebox etc can sit on top of it. Alternative find a heavy duty hinge, you have the contacts in spare shop so shop around. And try to add a sturdier lock system on the opening side to take the weight off, you can mount it inside if the available options are fugly. Best is to add the spare frame, since it will soon take the toll on the actual gate or the existing clamp etc ie assuming new tires are real heavy in comparison. Just curious how much of weight diff between old and new tires? shouldnt be more than a kilo right?
	() Thanks

13th May 2010, 07:22	#5
arjunrudra Senior - BHPian Join Date: Jul 2008 Location: Gurgaon/Chennai Posts: 1,577 Thanked: 197 Times View My Garage	Can't the Jeeps Tailgate be shut permanently. Mine is closed permanently as I was told the tailgate was to give sure shot problems with the chassis bending while offroading.
	() Thanks

13th May 2010, 11:32	#7
Tejas@perioimpl Distinguished - BHPian Join Date: Sep 2008 Location: Bombay Posts: 4,423 Thanked: 9,581 Times View My Garage	Motocamp, I'll check out your tailgate idea when we meet for the next recce. Arkaji, Thanks for the phone discussion. Will work on the gate rubbers this weekend and update.
	() Thanks

13th May 2010, 14:58	#10
motocamp BHPian Join Date: Jul 2008 Location: pune Posts: 452 Thanked: 102 Times	This is what the tailgate i have designed looks like now remember it is incomplete still in the design stage. But you can see it is strong ....with ram standing on it you can easily swing it shut due to the bearings around the pin and it does not wobble or sag. Attached Thumbnails
	() Thanks

14th May 2010, 12:34	#11
Tejas@perioimpl Distinguished - BHPian Join Date: Sep 2008 Location: Bombay Posts: 4,423 Thanked: 9,581 Times View My Garage	Kunal, how do you lock/secure the tailgate?
	() Thanks

14th May 2010, 13:02	#13
jeepster Senior - BHPian Join Date: Oct 2008 Location: MH24 aka LATUR Posts: 1,694 Thanked: 1,927 Times View My Garage	hi motocamp the tail gate looks a little inclined.
	() Thanks

14th May 2010, 14:21	#15
V-16 Senior - BHPian Join Date: May 2005 Location: mumbai Posts: 4,594 Thanked: 950 Times View My Garage	That looks like a great solution Kunal. If you guys had a CJ you would not be facing this problem ...or have i spoken too soon?
	() Thanks