Tailgate strut installation

[fiatslug87]

I wanted to add a tailgate strut to the WilderNest trailer so when we are inside with the tailgate closed and need to open it, it won’t just drop. Here’s what I did:

Parts:

1)     Tailgate support cables for 94-01 Dodge Ram https://www.ebay.com/itm/354347359527

2)     Tailgate strut kit for 07-18 Chevy Silverado/Sierra https://www.ebay.com/itm/295782351237

3)     Two 10mm Ball Studs (looks cleaner than modifying the brackets which come in the strut kit) https://www.ebay.com/itm/223293493196 (these are 5/16-18 thread)

4)     Washer to fit upper cable end (I used 3/8” washer with 0.81” OD)

5)     Bolt and washer to attach lower cable end to tailgate (I used a 1/4-20 cap head bolt, don’t want the head to be too prominent)

6)     Nutserts appropriately sized for the Ball Studs and bolt for lower cable end

7)     Blue Loctite

8)     Drill, angle grinder with cut-off wheel

9)     Drill bits appropriately sized for nutserts used

 

Procedure: recommend priming/painting any bare metal

1)     Remove tailgate strap bumpers from the left side of bed and tailgate (could install on either or both sides.)

2)     Remove upper strap support pin and braze/weld a washer to it to fit the upper cable end. If you don’t the cable end will try to kick to the center and could be hit by the tailgate bracketry. Reinsert pin.

 

3)     Drill hole in bed 8.25” up from top of the body mounted pivot bracket in line with the taillight mounting screws.

 

 

4)     Insert nutsert and fasten ball stud (could do nut/washer here.)

5)     Drill hole in tailgate 0.5” from end of tailgate pivot bracket, insert nutsert and fasten ball stud.

 

6)     Cut off left strap on tailgate at pivot point.

7)     Grind the pivot point flush with bracket and knock out remaining material.

 

8)     Drill hole for nutsert through hole in bracket AND tailgate for nutsert/bolt clearance.

9)     Insert nutsert into bracket (I removed the two Torx bolts holding the bracket in place and pulled it away to insert nutsert, may not have to.)

10)  Attach the upper cable end, you might have to slip the cable on the pin then attach pin depending on washer size. I ground down the top and end portions of the cable end so it would rotate without binding and I could slip it over the washer and rotate it into place.

 

11)  Attach lower cable end using bolt/washer, not too tight, cable needs to pivot, I used blue Loctite.

 

12)  Attach the strut, the two ends are adjustable, adjust so when the tailgate is down there is no load on the strut.

 

13)  When closing the tailgate feed the cable to the right of the strut, it may do this automatically.

Disclaimer: your measurements may vary

 

[jeff351]

great write up! Looks like i have another project to do now