07 custom rear hatch and roll pan

[Doubeleive]

Fixed it.

I was thinking more like $50k

 

[HiHoeSilver]

I'll take custom body work for 60k, Alex.

 

[Jason in DLH]

I’ve been thinking about how to do this for about a year now. Was once again under the Yukon briefly tonight looking at what would have to be done to accomplish this. Some quick notes I’m thinking needs to be done:

1. Disconnect rear parking sensors
2. Disconnect license plate lamp wires
3. Remove plastic bumper (remove or cut to length spare tire winch tube thing depending if you’ll keep the spare tucked under there)
4. Remove hitch
5. Shorten metal bumper to accommodate custom roll pan (I haven’t seen any company selling a pan)
6. There’s some stuff going on behind lower quarter panels that need repositioning or removing (I’ve gotta look more closely at this)
7. I believe at this point you could start welding in sheet metal which needs to wrap from quarter panel to quarter panel.
8. You could then drill new holes for backup sensors, spare tire tube thing, license plate lights. Could just use a ratchet on the spare tire winch and completely remove the tube thing that goes to the bumper.

Im not a body man at all so I don’t know how the new sheet metal can be contoured to match existing body lines, but obviously it can be done.

I believe if you were able to take care of all the removals and have a body shop install the new sheet metal only (no sanding, painting or anything) I bet you’re only looking at a $800 or less (maybe I’m dreaming). You could then bring it home and grind the welds smooth, body fill it, sand it, prime it, and paint it yourself in a weekend.

After a year of thinking about it I’m finally thinking it’s doable! Especially after seeing all those other trucks.

 

[ivin74]

I agree, lol

 

[VDV18]

Then install all of the bolt on parts, easy peasy

 

[Rocket Man]

 

[Jason in DLH]

I got to thinking more about this and remember reading about using styrofoam to temporarily attach to the body as if it’s the roll pan and then shaping it the way you want it while it’s attached to the truck somehow. Then you can make a fiberglass mold from that. I do believe I’ll be trying this and when I do I’ll post the results.

 

[Jason in DLH]

Of course you’ll have to glue a few thick pieces together and reinforce it to include both the quarter panel areas.

 

[Rocket Man]

OK enough of the talk, now get busy and do something. And don’t forget pics or it didn’t happen. That’s the rules. Anybody can make plans but talk is talk.

 

[Jason in DLH]

You have given me the right amount of motivation. When I started thinking about this last year we were still using the truck as the family vehicle and I really couldn’t have it all in pieces. Now that we have a new family vehicle I’ve got PLENTY of time to work on it. Just have to finish all the current work on it first...then I believe I’ll begin this project!