I am working on a tailgate for my 72 and found more rust (big surprise!) after I cut off the bottom to use the replace panel - the extra rust i found is on the inside bottom where there is a embossed line which I assume is for the weatherstripping and/or strength on the flat surface. I am inclined to just cut that whole section out and replace with flat stock. Anything wrong with doing it that way? i couldn't fabricate that relief in the metal again.. i could weld in a 1/3 of round stock of some sort and maybe get close but would like to avoid warping stuff if i can.

Also what is everyone using to repair the round ends where the hinge sits? Hole saw it out and hole saw a piece of flat stock and weld it in?

If you are worried the whole width is thin, then replace it with a flat patch. Cutting it out and patching it will give you better metal & a flange to weld or glue to.

I've seen a guy use freeze plugs that he welded into the ends.

You could weld in a flat piece there but just have to note that's where the seal touches the tailgate. You may then have to adjust the seal when you get to that point.

That's what I figured. I will evaluate the rot I think it would be best to remove that whole section the metal is thin in places.

the panel I have has that raised portion included....might get one with the same style?

yea, where? I'm in the same boat

What keith has looks like the top of the tail gate.

That's what I was wondering. I might be able to cut the embossing out of that and graft it in. But not sure it's even worth it.

ive got a bead roller and could probably duplicate a similar embossing if interested

Iam but your so far away let me see what I can do locally. I need to pick up a sheet of 16/18 gauge

Its the lower, picked it up from Duff's, the only issue with it is that the raised portion goes end to end.
Gonna need some hammer and dolly work to get it to look like the stock raised portion. Over all a pretty decent piece.

I will take a better pic tonight to show the whole thing...the pic I posted does make it look like the top piece though..

As you can see, they rolled it all the way out to the ends, take a little work to flatten off the ends for the stock look,

I went and bought some 17 gauge and found a shop to roll a bead on one side and bend up an approximation of the emboss. I think the thick one should work fine, I will just flatten off the ends and be done with it.

I'm glad you are doing something to replicate it. Only because its an eyebrow tailgate. You could sell/trade up if yours comes out nice enough.

Most of the welding is done. Took my time to make sure I didn't warp anything. Later this week I will grind the welds down, fill in any missing spots and fix the emboss on the ends so that it looks a bit more stock

Looks great!

Nice. Like the extra profile you added.

Starting to grind things down. Will sand and do more later this week. Rain put a damper on my workshop time.

Got most of the grinding done. Started working on flattening the ends of the embossing. Should have done this before i welded it in but I will make it work.

a little bit of seam sealer here and there and i think its good enough for now.

Looks awesome. Good work.

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Installed! Ruff!

Otis is ready for a ride to the lake