Rust repair

Pin_Head · 05-03-08, 11:39 PM

I threw in the towel on finding good used doors locally and bit the bullet by cutting out the rust and welding in new sheet.

Cut a piece of 16 ga sheet and bend and pound it into shape.

Check the fit often

Out with the rust, in with the new

Tack weld and then fill in the gaps. If the metal warps, peen the weld bead with a chisel point hammer across the bead to expand the metal.

Grind, fill, sand

Paint

Done. It needs some finish filling and sanding before the top coat is applied. About 4 hours, total, not including the time for the filler and paint to dry.

Texx · 05-04-08, 06:33 AM

Been there, done that, x1000. Your finished patch panel looks pretty much identical to the free ccot ones I got with the last 40 I bought. I only used a small piece of each one, so I could fix more doors as they come along. Nice work!

osagecruiser · 05-04-08, 09:43 AM

nice work pinhead...also been there only the repair was the result of a neighbor backing into jake.

osagecruiser

Wile E Coyote · 05-05-08, 12:47 PM

Looks good, BTDT too, and used my vice, as well. Mine was on the rear lift gate on my 62. I used a couple homebrew forming dies and a hammer.

05-03-08, 11:39 PM	#1
Pin_Head IH8MUD Lifer Join Date: Feb 2002 Location: OC, CA Posts: 5,015	Rust repair I threw in the towel on finding good used doors locally and bit the bullet by cutting out the rust and welding in new sheet. Cut a piece of 16 ga sheet and bend and pound it into shape. Check the fit often Out with the rust, in with the new Tack weld and then fill in the gaps. If the metal warps, peen the weld bead with a chisel point hammer across the bead to expand the metal. Grind, fill, sand Paint Done. It needs some finish filling and sanding before the top coat is applied. About 4 hours, total, not including the time for the filler and paint to dry. Last edited by Pin_Head; 05-03-08 at 11:49 PM.

05-04-08, 06:33 AM	#2
Texx IH8MUD Lifer Join Date: Feb 2002 Posts: 1,768	Been there, done that, x1000. Your finished patch panel looks pretty much identical to the free ccot ones I got with the last 40 I bought. I only used a small piece of each one, so I could fix more doors as they come along. Nice work! __________________ world's cleanest 89 FJ-62, and a few parts... 85 xcab hilux 4x4 resto'ed, 67 XKE, 1500 Vulcan, 80 Fj40 under resto..mine now! ! 03 Tacoma TRD SR5 Born to raise Hell! Right after my nap.

05-04-08, 09:43 AM	#3
osagecruiser IH8MUD Lifer Join Date: Nov 2004 Location: In The Storm Cellar! Posts: 1,619	nice work pinhead...also been there only the repair was the result of a neighbor backing into jake. osagecruiser __________________ 1968 fj40 under restoration and nearly complete! thanks to everyone here!!! 1972 fj55 1963 fj45 swb.... Tornado Alley Cruisers tlca member #14777

05-05-08, 12:47 PM	#4
Wile E Coyote IH8MUD Lifer Join Date: Sep 2005 Location: Lake Havasu and Kingman, AZ Posts: 1,011	Looks good, BTDT too, and used my vice, as well. Mine was on the rear lift gate on my 62. I used a couple homebrew forming dies and a hammer. __________________ ="Are you gonna sit there on that friggin computer all day or what?" The desert dwellin, roadrunner chasin, soooper-genius! '90 FJ 62, '08 Scion head unit, chopped quarters and rockers, bedlined exterior, and mostly stock. My soft wheeler and DD. '85 Dodge Ramcharger a little built, and a little beat. My hard wheeler.

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