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Old 12-02-2009, 10:21 PM   #1
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This little lip is stopping me from putting on my corner guard. Its the passenger side tailgate hinge, this part was covered by the plastic tailgate hinge covers (ones which I took off).

Any idea on how to get rid of that little lip?
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Old 12-02-2009, 10:37 PM   #2
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Bfh?

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Old 12-02-2009, 10:42 PM   #3
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id say pull off the tailgate and cut it off. a cut off wheel would work best. or take off the tailgate then install your guards and see if you can install your tail gate over it
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Old 12-02-2009, 11:06 PM   #4
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who would have a cut off wheel?
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Old 12-02-2009, 11:13 PM   #5
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Quote:
Originally Posted by Rawkon View Post
or take off the tailgate then install your guards and see if you can install your tail gate over it
I'd go with trying this first. Easy to do and you don't have to cut any.

2nd option for me would be to trim the corner guard to fit without cutting the tub.

Cutting wheel = anglegrinder with a cutting disc // air tool with cutting disc. Could get a grinder and cutting disc cheap or Any muffler shop could do it for you.
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Old 12-02-2009, 11:15 PM   #6
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Ahh awesome thanks. Well I think id rather cut that little lip off since its not that much use to me, while with the corner guard its been painted and id need to sand off and all that. Im seriously looking at an almost perfect fit had that little 1cm lip not been there.
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Old 12-02-2009, 11:33 PM   #7
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Doesn't that "little lip" hold on the tailgate hinge cover?

I'm guessing...my work comp blocks the picture from me seeing it.
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Old 12-02-2009, 11:37 PM   #8
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the little lip holds the tailgate hinge plastic cover. Something not Necessary, and something id forego if my corner guard would fit. I also believe alot of jeeps take off the plastic covers anyways.
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Old 12-02-2009, 11:42 PM   #9
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Have at it then bud. For just that little tab I believe you could hack it of with just a Dremel with a small cutting disc. I'd remove the hinge...cut the tab off then stick the hinge back on.

Plus it's always nice to have a dremel.
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Old 12-02-2009, 11:48 PM   #10
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I dont believe my dremel will cut through that thick of metal. its pretty thick. Would I just get a buzz saw for my dremel if I wanted to? I also have a circular dewalt 18v saw sitting around. But god, it took Jerry 2 hours to put these on, I spent 4 hours and all i got was pain. Im really wondering if the slight differences in the years on his Jeep and mine, is making this so painful.
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Old 12-02-2009, 11:55 PM   #11
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The dremel will work, they now have a heavy duty cutting disc. You can pick up at lowes or most any hardware store. I've cut 3/16 steel with them before. slowly but it cut just fine.

DO NOT use a circular saw to cut them...that's just asking to get hurt.
If you take the hinges off just ...take them to any autobody shop or even a muffler shop. And they can cut the tabs off or grind them off. Probally for $5.
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Old 12-03-2009, 12:01 AM   #12
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Awesome, Ill keep that in mind this weekend. Other than the name "heavy duty cutting disc" do you have an exact name?
also mine is 35,000 rpm, how much is yours?
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Old 12-03-2009, 12:04 AM   #13
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Quote:
Originally Posted by terrible2 View Post
Im really wondering if the slight differences in the years on his Jeep and mine, is making this so painful.
If your talking about "jerryb"???? Then there IS a difference between your tailgate hinges and his. Jerry's is a 97 yours is a 05... the hinges on your are stamped steel with plastic covers. Jerry's will be a solid hinge made of pot metal.

You know what yours look like..here are pic's of the hinges uses on the later TJ's such as JerryB's.....

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Old 12-03-2009, 12:08 AM   #14
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This explains why im having trouble. And yes the JerryB, hes helping me out this weekend since I bought the corner guards from him.

Also for your model and his, was the gas cap cover also in a slightly different spot? with those corner guards, I really had to mash it into the tub so that it could go around the gas cap cover. Which slightly explains my loose pop rivets.

I dont suppose I can swap out hinges at a junk shop would I? (if it came down to it)
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Old 12-03-2009, 12:12 AM   #15
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Awesome, Ill keep that in mind this weekend. Other than the name "heavy duty cutting disc" do you have an exact name?
also mine is 35,000 rpm, how much is yours?
My dremel has adjustable RPM but goes up to 35,000 rpm as yours should.

Here is a link to the disc I use for small metal cutting such as what you have... the part # is on the page..."at lowes".

Dremel at Lowe's: 5-Pack 1-1/2" Metal Cut-Off Wheels

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Old 12-03-2009, 12:15 AM   #16
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I may end up going to Lowes depending on the route we decide to go, only $10. Mine may be adjustable too, but I got it as a package with other tools from this guy, so I really dont know how to work it.

Thanks for the help, it gives me a little head start on the weekend.
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Old 12-03-2009, 12:42 AM   #17
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I have the stuff we'll need to cut that tab off, it'd take forever to take it off with a Dremel. See you Saturday Albert.

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