Tailgate Cable Alternative

[Glen Baker LLC]

Glen, I don't know. Good question. I know they haven't always been, if they are now.

I had a heck of a time finding a picture, but here's one of a similair design to what I was thinking.

I'm not saying my idea is best either, just wondering as I am curious. Maybe someone here knows more.

Jeff, I just checked. The cables are not stainless steel.
They can rust.

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[Blue316]

Jeff, most excellent question !
I’m with you on this. Early tailgates used chain which where far too clunky. The flat plate hinged stops definitely make the most sense. If I was more capable I’d go to the garage and whip up a fix. They really are that simple. The most difficult part is the hinge rivet. Well you got my brain spinning.

 

[Jeff D.]

Jeff, I just checked. The cables are not stainless steel.

Ok. good to know. They weren't on my Chevy either, and I would've never been able to tell the connection at the eyelet was corroded before it failed. It had a plastic cover over it which made it appear uncompromised.

The general consensus seems to be cables are fine, so I'm going to drop my hair brain idea.

Opp!, I just saw Reggies response. So maybe I'm not crazy after all!

 

[MakinDoForNow]

"MakingDoForNow" James,
This is what I found on the forum.
It isn't a folding support though.

I do remember that. I think I saw one that folded also, but who knows. I have seen a telescoping one also somewhere else (for dirt bikes?) that hangs on the latch pin and clips into the latch. It was adjustable by putting a pin through a hole drilled for desired length. DG makes scissor type but doesn't show length for Maverick so would have to modify it for length.

 

[MakinDoForNow]

Jeff, most excellent question !
I’m with you on this. Early tailgates used chain which where far too clunky. The flat plate hinged stops definitely make the most sense. If I was more capable I’d go to the garage and whip up a fix. They really are that simple. The most difficult part is the hinge rivet. Well you got my brain spinning.

The hinged rivet can be purchased and the straps can be attached to it. Most likely they can have a ball bearing swivel or you can buy a bearing for a wind spinner about 3/8" thick. (????)

 

[ThisWas]

The Maverick tailgate cables are easily detached then reconnected to different mounting points to enable the tailgate to be partially open.

 

[Howard]

I'd suggest protecting the cables with some spray lube once a year and if you're really concerned, replace them after 10 years.

 

[oysterville]

Thanks, John. I do have one of those and like it.

The linkages I was referring to would replace the cables for limiting the tailgates travel. I've noticed the tailgate seems to go past "level" when a load is on it, I'm nervous about cables breaking when the tailgate has a load on it, and Mavericks have had issues with the cables not being the same length. One cable takes a disproportiante amount of the weight when it's like this, and can cause a twisting stress is the tailgate when it happens.

The linkage (arms) I am thinking of were used for many years and seemed like a good idea. There may be a good reason cables are better, but I don't know what that would be.

In my example below, if the cable were to break my snowmobile would certainly be put in a dangerous position for me and other motorists. That's my fear. I'd be more comfortable with the old style arms in that instance.

Cables don't pinch fingers.

 

[Potatomafia]

After a quick web search, I found a company that manufactures tailgate support bars. I know they don't fold up when closing the tailgate but maybe you could fab up something similar?

https://dgmtailgatesupport.com/

 

[jonshep]

In the days of old, pickup tailgate were equiped with chains with hooks. I would post a pic but the 51 Chevy is at my boy's shop. They ran those thru a garden hose to keep them from banging. Those got replaced with the folding straps that were mostly hot dipped galvanized. As we all know, the straps were replaced with the cables. IDK what they are made of, but I suspect junk. I did find that you can buy stainless cables. Not sure they make stainless to fit the Mav yet. I think DGmfg makes a solid strap for max load, but it doesn't fold.

https://dgmtailgatesupport.com/product-category/tailgate-support/

Dgmtailgatesupport.

 

[Shock96]

So a quick look at some wire charts show that standard bright 1/4" cable has a minimum break strength of 5480lbs. Safe load is 1100lbs. Not sure exactly what the cable size is, maybe a bit more than 1/4" so I wouldn't worry about the cable breaking from weight.

I have a 2001 Dodge 1500 with the cables and they are perfectly fine.

On the tailgate hinges, it is hard to tell what the size of the rivet is, but probably 3/16"? That has a shear strength of 860lbs. It could be 1/4" and that is 1555lbs.

So I don't think there is anything to be gained in the strength department and you do get the nice option of crushing a finger in there.

 

[MetalsGeek]

...but it could be also that there were some people that lost fingers in the linkage-guillotine apparatus.

Some years ago, I built a welding table that folded down for storage, and used flat cold rolled steel links (under compression) to support the top. My original plans were to add hydraulic dampers so the top couldn't fall quickly when the supports were unlocked and pushed off-center, but I ran out of time and never got around to it. Last year I was daydreaming and you can guess what happened. The photo shows the table in mid-travel, and how the linkage creates a scissors. There's a fingertip in those gloves on the floor in back. (LOL) I'll spare you the medical photos, but suffice to say that you may well be right on the cable's improved safety!
Stupid is as stupid does. I'm smarter now, and try to be more mindful in my shop!

 

[icegradner]

Perhaps I'm missing something? I'd be interested in replacing my cables, if an aftermarket design similiar to the earlier ones were offered for the Maverick. I'd certainly be less worried when carrying a load on the tailgate, which happens on the Maverick alot more due to the short bed.

Why move away from that design? Most likely strength, points of failure, and cost. You'd have to ask an engineer, but that system in the picture appears to have a minimum of 4 obvious points of failure for one thing. Like many changes to vehicles over time, that old design is likely more labour intensive, and thus more expensive to manufacture.

 

[Carlitos_92]

Some years ago, I built a welding table that folded down for storage, and used flat cold rolled steel links (under compression) to support the top. My original plans were to add hydraulic dampers so the top couldn't fall quickly when the supports were unlocked and pushed off-center, but I ran out of time and never got around to it. Last year I was daydreaming and you can guess what happened. The photo shows the table in mid-travel, and how the linkage creates a scissors. There's a fingertip in those gloves on the floor in back. (LOL) I'll spare you the medical photos, but suffice to say that you may well be right on the cable's improved safety!
Stupid is as stupid does. I'm smarter now, and try to be more mindful in my shop!

Yeah, you may make it to the end with all your limbs and digits if you're lucky, but if you live long enough, most of them will have scars.

I like to show my adult daughter the scar where I cut a pumpkin-seed-sized piece of my fingertip off with an X-acto trying to frame art for her room, the weekend before she was born. The blood made a mess, but I enjoy having the story and the odd remembrance of that time.

 

[Jeff D.]

Thanks all for sharing the knowledge and stories. Much appreciated!

Perhaps my one bad experience has had too much impact on my feelings towards tailgate cables.

It sure "feels" to me like those old linkages would be stronger, but I have no evidence that it's true. Perhaps it is the opposite?

Also, I never considered the possiblity of pinching a finger, although I guess it could be possible.

My experience with cables in general hasn't been positive. Broken winch cables on my 4 wheelers, cut hands from recoil cables on the old snowmobiles, but like anything, inspecting and replacing when needed is key.

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