[cps]

Ok, so I searched high and low and no one makes a aluminum diamond plate tailgate protector. So....I decided to build my own. I wanted this protector to be a complete bolt on project because I might mass produce these if I get enough inquiries. My protector replaces the old style black plastic cover (pictured 2005-2007) and the new style black plastic cover (not pictured 2007 to current).
Details:

-1/8" thick aluminum diamond plate
-rounded inside corners
-sits flush and right up against factory top tailgate protector (black plastic one)
-12 recessed 1/4" stainless steel screws (included)
-12 1/4"x20 jack nuts (included)
- spacer washers (included)

Install steps:
1) remove all hardware from old black plastic protector and remove protector
(The top of the old protector has double sided tape all the way from left to right so a paint scraper works great to pry your way across)
2) elbow grease time: use a plastic scraper and rubbing alcohol or Goof Off and remove double sided tape from the tailgate. (Now is a good time to clean the rest of the tailgate)
3) remove and set aside upper access panel (it only goes on one way and it is directional)
4) remove nylon square nuts from sheet metal
5) get your drill and a 7/16" drill bit and CAREFULLY DRILL out the 8 square holes you removed the nylon square nuts from. (If you are not careful your drill bit will dent the other side and leave a little dimple showing on the outside.....I did this on one hole! Haha)
6) now drill out with 7/16" bit the lower 4 holes closest to the bumper
7) insert 12 jack nuts and proceed to sandwich them in place. (Please watch how to videos on YouTube if you are not familiar with properly installing jacknuts)
8) place access panel back where it goes
9) install spacer washers at all 12 holes
10) set aluminum diamond plate protector where it goes
11) install 12 stainless bolts but leave loose until all 12 are threaded in by hand
12) tighten bolts by hand starting in the middle and working your way to the outside. Once they are all snug, using an 1/8" drive INCH pound torque wrench (NOT FOOT POUNDS PEOPLE), torque them to 35 in lbs.
13) wipe your sweat and finger prints off with warm soap and water and ENJOY!

Thanks,
CPS

Before (more pictures to follow):

 

[cps]

After

After:

 

[cps]

Rounded corners

Rounded corners:

 

[cps]

Flush mount screws

Flush mount screws:

 

[cps]

Jack Nut and Screw

Jack Nut and Screw:

 

[cps]

If anyone is interested, please send me a PM!

Thanks,
CPS

 

[shift_RUSH]

Cool mod! Any idea how much the plating weighs?

 

[cps]

Weight numbers!

Ok, so I went back out there and took it all back off so I could weight it! Lol
It was on my list, but a forgot!

1) the old black plastic protector weighed in at 5 lbs
2) the diamond plate weighed in at 12 lbs

So, with the diamond plate installed and the old plastic protector removed, the tailgate is now 7 lbs heavier than before!

CPS

 

[eswartz]

Very nice, looks great. What was the approximate cost?

 

[cps]

Price!

I'm still working with my local metal supplier on giving me a better price on the aluminum if I buy I bulk. My protector is built by hand, and takes about 3 hrs to build.

So, I would say around $130 plus shipping (I haven't checked as far as shipping rates go). That price includes all stainless steel hardware, jacknuts, and spacer washers.

CPS

 

[cps]

Took a picture from the side this morning:

 

[cps]

Uninstalled protector with spacer washers installed:

 

[cps]

Another view:

 

[cps]

Close up of flush mount bolts:

 

[cps]

View with tailgate closed:

 

[whistler]

Looks good. Is your material supplier going to cut your diamond plate to size?

 

[jon_bransford]

That is amazing Chris, my gate is bent from loading a 800 pound mower in bed.
Gosh wish my bed was not messed up I would do this in a heart beat.


Sent from my iPhone using Tapatalk

 

[cps]

Yes, all four corners are shear cuts, straight, true 90 degrees, and clean!
I do the rest.

CPS

 

[whistler]

Excellent!! No cutting fee? Even if there is,it's worth it.

 

[eswartz]

Again, looks great. How did you get the holes to line up with the existing holes in the tailgate? Great idea, may be doing this soon myself.