How to Repair Expanded Steel Trailer Tailgate DIY

Fix that gnarly trailer tailgate of yours already! If this applies to you, check out this video for some tips, tricks, and tools for getting it done correctly BEFORE somebody gets hurt on it.

If you do decide to go the route I did, here are links to tools and parts used in the video to help you do it:

Norton 4.5″ grinder flap disk: 

Inkzall (the BEST shop markers I have ever used):

Black  & Decker Grinder (this is a Porter Cable but Stanley tools owns both Black & Decker and Porter Cable, it is the exact same grinder):

The trigger type grinders are the way to go. I HATE the ones that have the odd button up by the handle that can be locked on, I think they are awkward to use and dangerous. This style is much better.

Lenox 4.5″ Diamond Cutoff Wheel:

Ryobi 18V OnePlus Grinder:

6AH Ryobi High Capacity batteries:

Orange Welding Jacket with Pen Pocket:

3M Reusable dust/grinding/welding mask:

Irwin Welding C Clamps:

Hobart Handler 190 (the newer version of mine in the video):

This is a great hobby welding machine. I have put mine through almost two decades of use. Other than replacing the gun and liner a couple of times from normal wear, it has done great. The only actual issue I have with it is during bigger/thicker jobs where I hit the duty cycle limit and have to let it cool down mid-job (this one is 30% duty cycle, higher duty cycle unit are WAY more expensive). This doesn’t happen enough to be an issue, I just take a break and work on something else for a bit.

This is the way I did it, I would love to hear your feedback on what has worked for you in your shop.
Hope you get some ideas!

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