I agree, but that looks GREAT!!! ...and you will be able to sleep at night knowing you did it RIGHT!!!
I did this on my blue 77 and am about to do the same on my red 78... although, I am not taking the red one completly off the frame like I did...
On the outside I was just going to clear coat it and keep it as it is. Not sure what to do on the inside I was thinking to POR-15 in clear to seal it or I can completely repaint it. What do you think?
Your 40 looks like the twin to my '69. I'm starting to cut out rusted areas and replacing with new metal: rear sill, lower rear quarters and 2 small patches on outer rockers. Only way to really keep it from getting worse. I'm not planning on a...
I agree!
I recently completed a rear sill replacement on an FJ40 model similar to yours, which had comparable issues and goals. I’ll attach the link below for reference.
Here is my two cents:
I appreciate the appeal of patina; it has a unique...
So Tuesday I did a thing…
Loaded up the 40 with a buncha parts, and was on the road a 4:45AM (to hopefully beat some of the heat) to head 7hrs down the road to Winter Park, FL to meet the gang at Cruiser Matt’s Off-road and leave the 40 behind...
Here is the thread I made where I explain the sill replacement in much more detail. Thanks @jesus888 for letting me work on Old Blue Eyes!
https://forum.ih8mud.com/threads/how-to-replace-rear-sill-fj40-step-by-step.1363939/#post-15988603
More pics...
Again, take your time and make sure you don't get the metal too hot and cause it to warp.
Also, notice how the tire rack holes line up perfectly.
*** Step 10 ***
After ensuring the sill and the cover fit perfectly, clamp it down and "plug weld" the new sheet metal sill cover to the bed floor and the sill.
- Notice that there is plenty of good metal under the cover to attach to the bed...
*** Step 8 ***
Paint and test fit the new sill by installing it with the new bolts and body mounts.
* I highly recommend getting new body mounts and bolts. They are not expensive, and you will likely break a few old ones in the process.
- Be...
**Step 1**
Begin by removing any obstacles, such as the spare tire rack, bumperettes, rear doors, emblems, etc.
You will have to remove the spare tire rack because it is attached to the sill.
You do NOT have to remove the doors and the...
**Step 2**
Next, remove the old body mounts located under the sill and attached to the frame. There are a total of four body mounts to take out.
- I recommend you hit the bolts and nuts with some penetrating oil to help break them loose
- Use...
**Step 3**
Remove the outer sheet metal sill cover. Take your time and cut it out piece by piece if necessary.
** Be careful not to cut into the bed floor or wheel wells **
**** Especially be careful NOT to cut the bed floor under the sheet...
Most likely vapor lock caused by ethenol in the craptastic summer blend fuels found in Colorado. Find pure fuel and see if it helps. Put some heat shielding on the fuel lines and route away from heat sources. An inline electric fuel pump rated...