The build process for the tailgate panel is very much like the previous 2 panels. Here is a shot of the panel after fiberglass.
One thing I did do differently is I installed the ash trim on each end and then filled it with the cherry strips. That eliminates the need to cut the cherry strips after they are glued on the forms. The downside is that it is not that easy to get the strips cut to a size that gave a tight fit and then not have them shift while gluing. I am not sure when method is better.
With the fiberglass polished I can now add the ash trim on top.
While this is going on I am also working on the logo that will go in the middle of the tailgate. A year ago I posted a blog series about making a blank for VW logos. I hinted at the time that it was for a future project and this is it.
I set the blank onto my crosscut sled with a location stop. I cut the blank as thin as I could.
I made several passes – rotating the blank after each pass.
The final cut was with a hand saw as the table saw blade could not reach.
After gluing a layer of plywood to get the logo to a final thickness, I trim it to size with the router.
After taping a sheet of 60 grit to the tailgate panel I can shape the logo backside to match the curvature.
Here’s a shot after I start. I have to remove about 1/32” to get where I want to be.
Now I can fiberglass the logo. I’m doing this to increase strength and stability. It is also a very good moisture barrier.
Here it is after the fill coats. I still need to smooth and polish it.
Now it’s time to make the trim ring for the logo. I’m using two layers of segmented ash rings.
The next step for the ring is to cut an inside circle that matches the final outside diameter of the logo and the largest outside diameter that will work. I’ll use the CNC for this.
I also made some progress on the driver’s side door panel. The back side has fiberglass.
The panel edges have been cut to match the ash trim.
And I masked off the inside of the trim. This allows me to fill some gaps between the trim and the panel when I epoxy the trim.
The blog is caught up at this point. I’ll be completing the driver’s side and tailgate panels. Then I can move onto the final set of panels for the bed sides.
I HAVE been watching this project all along just have not been commenting because i was trying to figure out just what was going on now im starting to see the light WOW 👍
