INSTALLATION INSTRUCTIONS
TAILGATE HANDLE RELOCATOR
****81-87 REQUIRES PART # 1189200****
ACCESSORIES SOLD SEPARTELY:
TAILGATE SKIN
PART #1178661
For best results, please read all instructions thoroughly prior to attempting installation of your SIR MICHAELS tailgate handle relocater. SIR MICHAELS recommends the use of approved hand, eye and ear safety equipment while performing this installation. If you have any questions concerning the installation of your SIR MICHAELS tailgate handle relocater please contact our customer service department at (714) 379-6800, Monday through Friday between the hours of 10:00 a.m. and 4:00 p.m. Pacific Standard Time (PST). NOTE: Any part that is modified and/or painted are non returnable.
1. Remove the tailgate from the truck and place face down on saw horses or work bench. NOTE: IF USING A SKIN, HANDLE RELOCATER MUST BE INSTALLED BEFORE THE TAILGATE SKIN IS WELDED-ON.
2. Remove the three screws that hold the handle in place, unhook the rods and then remove handle from the tailgate.
3. Remove the end latches from the tailgate and set aside.
4. Measure areas for cut-outs using diagrams A Fig 1 . Use a die grinder or jigsaw to cut out marked areas Fig 2. When cutting out the back side, be careful not to cut through front side, as the two skins are close together (Fig 3). On the front side, Cut the tap that is spot welded to the tailgate. This will release the complete cut out part from the tailgate. See Figure 4.
5. After all cutting is complete, reinstall end latches into tailgate with the ends of the rods pointed up. The rods will now push up into the handle.
6. Bolt your factory tailgate handle into the SIR MICHAELS relocater. Place the relocater into the back side of the tailgate. Hook up the latch rods onto the handle. NOTE: Over a period of time the rod clips tend to detriorate, some times it is necessary to put a tack weld on the rod so it will stay in place.
7. Mount the relocater to the tailgate using the ten #8 screws provided. Once mounted, test the handle making sure it moves up freely. WD40 works good to loosen it up a little. Turn the tailgate over (original handle opening up) and grind paint off the area around the tailgate handle recess (approximately two inches fig 5) and weld the SIR MICHAELS provided filler panel in place, Fig 6 & 7. NOTE: DO NOT ATTEMPT TO WELD ONE CONTINUOUS BEAD AS EXCESS WILL DAMAGE OUTER TAILGATE SKIN.
8. Finally , grind down the welds, apply body filler, block sand, (Fig. 8,9,10) primer, and paint to match the outer tailgate skin. Now you are ready to re-install the SIR MICHAELS tailgate handle relocater equipped tailgate back into the truck.
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