Smooth tailgate Q's

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Smooth tailgate Q's

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Ben

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Has anyone had the privilege of watching anyone do a smoothed boot? I have a couple of Q's about it, as I am considering doing most of the work myself.

The metal plate which is welded in, can it simply be flat, or should I try to curve it more to the tailgate profile-so as to use less filler?
Do I cut the plate a little too big and try and fit it ‘inside the tailgate and then weld it in, or try to make it exactly the same size as the original hole and weld it/grind until flat?
Is it best to weld a full seem all the way around the panel, or tack it on in a few places to it ‘floats' a little tiny bit?
What is the best sort of filler for this job?

I have seen this item, http://www.dragon.istore.pl/sklep,405,11063858,93428164215676,03,,en-eur,57998,0.html, posted by nico, but unless it is actually curved to match the tailgate, cant see the point in buying it. I just plan to take the rear handle out and make a template from that and file until it fits.

Any help appreciated,

Cheers,

Ben.
 
get a flat metal plate and work it roughly to shape slightly bigger than hole

weld it on the inside of the boot (seem weld it start off spot)

prep strip the paint on the outside of the boot to bare metal and start building up the filer (use p38 filler)

once roughly in the shape you want strip the whole boot down to primer level (atleast get all the lacker off to get a key for paint) then prime the filled area with filler primer

let it dry then sand it down again and you will see all the dips and bumps in the filler where the paint isnt rubing away.

keep sanding until its all smooth and repeat the filler stage again then reprime and rubdown again then prime then paint

put on car done!
 
that panel is only a cover to replace the handel i dont think it was intended for moulding in to the boot you can try but being plastic i would expect the filler to crack when it flexes plastic bonded to metal is never a great idea
 
ash is right.....dont fill in the plastic it will always crack!
 
ahh i thought it was metal, never mind,

Pete





DONT WORK FOR THE CO-OP THEY DONT PAY PERIOD!
 

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