Traveler Liftgate cut down

J

jmalloy

Member
Hey!

I have a 1980 traveler with hard top and liftgate. I picked up a terra tailgate to use when I have the hard top off, and now that I've gone through the hassle of removing the tailgate so that I could put the liftgate back on, I'm thinking there has to be a better way.

Has anyone out there cut down a traveler liftgate to mate to a terra tailgate? This seems like it should be possible. Specific issues:

  • struts - current mounts are too low to use, and the cut-down top will be a lot lighter. Can I move the posts and replace the struts with Scout II liftgate struts? Is there a better way?
  • latch/lock - there's no room to move the existing latch mechanism. Thoughts on replacements? I'd prefer to be able to lock it... Also, can I move the liftgate lock to the tailgate? (seems like yes, but I'm wondering if there's some "gotcha". I realize I'd need to move the whole mechanism, not just the button.)
  • lower lip - thoughts on how to fabricate a lower lip and gasket to seal the gap between tailgate and liftgate? How much clearance would you leave between the two? (tailgate has a stepped top edge)
  • formerly metal parts - I vacuumed a whole bunch of rust out of the liftgate when I cleaned it up ( a truly impressive amount). I assume I used to have a whole bunch of metal. Does anyone know what the original reinforcements looked like in the tailgate? If I don't cut it down I May want to replace/reinforce the structure.

The obvious suggestion of grabbing a Scout II liftgate is a non-starter - the traveler has a sloped back end. The Scout II liftgate isn't even close to the right size/shape.

Even if I decide this is a good idea I won't actually do any work on the liftgate until spring - it's back on the Scout, and I'm not touching it until I pull the top next year. I will take lots of pics and post details if/when I actually cut down the liftgate.

As always, thanks for any thoughts/suggestions! I'm not looking forward to swapping all these pieces around again next year.

--jim
 
On the binder planet there is a whole write up on the "how to". Just use the search function and it will bring up quite a few
 
Thanks! This one: traveler tailgate??? - binder planet forums Answers some, but not most of my questions.

I'll keep researching, and post what I find here. Any other thoughts would be most appreciated. The cut seems pretty straightforward. I'd like to end up with something that might pass as stock to someone who didn't know better. That's going to require a little more fabrication.
 
Perfect!

Thanks for the link. I know I don't search that well, but I doubt I ever would have found this one embedded in page 14 of 43 of thedon's build guide. (what an amazing job! Part of the reason for the delay in replying was that it took me that long to go through the whole thread.)

from the pictures, the struts don't need to move but the lower rivet on the strut mount will need to be cut off. I'm ok with that...

I'm not sure I like his latch mechanism any better than the dual handles from the first post. I'll keep researching to see if I can find a solution I'm happier with. I'd like something with a single locking t-handle centered on the door with latches on either side. I'm not sure there's room for something like that. We'll find out after I cut the liftgate.

The lower lip he built looks good. I'll probably try to do something similar. Seems pretty straightforward, but I like the pictures to get me started.

I'm no longer worried about the pile of rust I pulled out of the liftgate. I've pretty much decided I'm going to cut it down, so structural reinforcement is less of a concern.

Thanks to everyone who replied for the help! I'm still looking for alternatives on the latch resign. If you have any more thoughts on the topic, please let me know.

--jim
 
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