Tailgate Hole revisited, with easy solution

[Lane]

Since the prior thread on this topic is closed, here's what I did to address it.

A past truck I owned had rust come through the paint on the bottom of the tailgate and it started to appear about 3 years from when it was new. I'm convinced it's from dirt, wood chips, leaves, grass, and everything else making its way into the tailgate vent holes. It sits in there for years and retains moisture and rusts it from the inside out.

Before I hauled anything in my Maverick, I wanted to reduce the odds that this was going to happen here. It'd be easiest to put some butyl tape right over it, or as others have suggested, 3D print a cover for it but I don't think those are good options as they'd reduce the airflow provided to the inside and make it even more likely to hold moisture.

In the existing tailgate hole, I added a zip tie to the harness which exits the hole to hold it to its plastic fastener better so it wouldn't move around as much as the gate is opened/closed. I cut a piece of fiberglass window screen a bit bigger than the hole, and notched out a spot on one end for wiring clearance.

I masked off the hole, then applied a couple millimeter layer of clear silicone around the perimiter. Embed the screen in the silicone.

I don't know if it will keep everything out, but it will certainly be better than it was. The fiberglass screen isn't the strongest, but I'll be installing a tailgate gap cover shortly to keep the big stuff out of the gap completely. And if I ever need access into the gate through that hole, the screen and silicone can just be peeled off.

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[campngolf]

Very clean solution. Nice work.

 

[tom_tucker]

That's awesome. Thanks for sharing. Man, you're full of piss and vinegar. Get as much done in the first 100 days while you have the most motivation. At least that's what I've experienced after 8 months. Too lazy now for the final mods.

I really want to add the tailgate gap seal (and screen cover) and bed cap lights to finish this build. The only good thing about the gap is water drains easily. Beyond that, you have to visually check the gap each time before you close the tailgate to avoid damaging it. I may just only add your screen cover. Thanks again for the screen idea.

 

[RichardCranium]

Neat idea! Have you done something like this before? How does the silicone last in terms of longevity?

 

[Lane]

Neat idea! Have you done something like this before? How does the silicone last in terms of longevity?

I've used silicone outdoors in a harsh environment (Wisconsin, temps range from -40F to 95F) and it holds up. Note that this is 100% pure silicone, different from typical household latex caulk which isn't as tough. In this case, it won't see much sun or water as it faces downward when the tailgate is closed. The screen is the weak point and would be easy to damage with a shovel or rake, branches, bark, and whatnot. I used the fiberglass screen because I already had some on hand. If a person buys some for this specific purpose, aluminum or stainless screen would be a more durable choice.

 

[mikeakasully]

Also, I would recommend using Fluid Film and use the straw to spray inside it. Clings to metal surfaces, but breathes and keeps water away. I also live in Wisconsin and will be coating the underside and inside all sorts of spots I can to keep the salt away. https://amzn.to/3RA2w1i

 

[RichardCranium]

I've used silicone outdoors in a harsh environment (Wisconsin, temps range from -40F to 95F) and it holds up. Note that this is 100% pure silicone, different from typical household latex caulk which isn't as tough. In this case, it won't see much sun or water as it faces downward when the tailgate is closed. The screen is the weak point and would be easy to damage with a shovel or rake, branches, bark, and whatnot. I used the fiberglass screen because I already had some on hand. If a person buys some for this specific purpose, aluminum or stainless screen would be a more durable choice.

Thanks for the insight. I was only asking because I used some 100% silicone in my travel trailer and it was peeling up after a couple years. Since my plastic sink is a different surface than paint, I was curious of your experience.

 

[P99Guy]

I don’t think the holes are designed for additional airflow. I believe they are there to ease the manufacturing process.
That being said I have attached an image of a snap in, removable, 3D printed cover that covers both holes and allows airflow. It is the first test of an excellent design by Richard Cranium. I will provide more images as we tweak the design.

 

[Mightybeast]

I don’t think the holes are designed for additional airflow. I believe they are there to ease the manufacturing process.
That being said I have attached an image of a snap in, removable, 3D printed cover that covers both holes and allows airflow. It is the first test of an excellent design by Richard Cranium. I will provide more images as we tweak the design.

I wonder when it will go on sale

 

[RLmesc]

P99guy, please let us know when it is ready for sale, I’ll take one in black, like Henry Ford offered.

 

[TrailMaster]

P99guy, please let us know when it is ready for sale, I’ll take one in black, like Henry Ford offered.

+1

 

[Kevin Senior]

+1

Me too, me too!!

 

[grod]

These shared solutions are what I've come to appreciate most about the forum. I have an impact bedrug with a gap filler, but I will be adding something similar to mine.

 

[cyberdog]

Richard Cranium has some stuff on Thingiverse, for those wanting to print themselves, but not that grate yet. I was considering the screen using self adhesive screen repair tape myself, but the grate, being easily removable would be an excellent option.

Will he be releasing the file on Thingiverse, or selling them?

 

[P99Guy]

I wonder when it will go on sale

I'm not that Guy. It Will be up to the actual designer of the product as to how they are made available.
we still have some design and testing to do.

the Designer does not have his truck yet so I am the test dummy!

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