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  1. cruiserpilot

    BJ74 rear quarter replacement

    I didn’t realize I didn’t update the final paint. Here it is.
  2. cruiserpilot

    BJ74 rear quarter replacement

    Stealth Custom Series F5 17x9 3.5” BS Toyo MT 285/75R17
  3. cruiserpilot

    BJ74 rear quarter replacement

    Yeah, lots of thumbs up and high fives! I have it down to 20 min for removal, about 45 to put it back together
  4. cruiserpilot

    BJ74 rear quarter replacement

    All done except paint. The roll over was bad enough that even the window frame on the RH door was bent out over 1"!! I managed to find a donor with clean rust free convertible doors, and another donor with rust free full doors. So summer was convertible, and I just yesterday finished the...
  5. cruiserpilot

    BJ74 rear quarter replacement

    Not that good!! I use a flapper wheel on my 4 1/2" grinder. Care has to be taken so as to not take the surrounding material away. I use the 80 and 40 grit flapper disc. Mine are no name brand, I have some that are made by JET Powerblend in 4 1/2" and 5". I also bought some glazing putty for...
  6. cruiserpilot

    BJ74 rear quarter replacement

    Anyhow, after degreasing and power washing the t-case is good. Appears the oil filter was a slight bit loose. All good. Back to finishing flare holes tomorrow.
  7. cruiserpilot

    BJ74 rear quarter replacement

    Kind words, very much appreciated. Has me looking at the 'undamaged' side, and I know that the whole of the bottom of the B pillar is the same. Ugh! Won't have time for it now. I've got to see about wheel well patch panels for BJ74, I sure don't want to replace a whole panel for some rust...
  8. cruiserpilot

    BJ74 rear quarter replacement

    last 4 pics, primer on, --- waiting to find missing antenna so I can put the front fenders on, replace the windshield, get it inspected.
  9. cruiserpilot

    BJ74 rear quarter replacement

    So after 5-6 or 10 off and on prefits I got to the tacking and it is complete. About 25-30 hrs including the repairs and fab of all the little bits and pieces. I used my Jack-all to cross push the top of the rear corner back 5/8". I got it pushed to the right spot, one click and I heard metal...
  10. cruiserpilot

    BJ74 rear quarter replacement

    Last 4 pics to round out the day. I went around and used weld through primer - good stuff from ProForm. Once that dried I taped all the future spot weld lines over to protect them. I also got covered in seam sealer and did the inner wheel well seam and all the other seams/welds that seemed...
  11. cruiserpilot

    BJ74 rear quarter replacement

    Now I have to deal with the freakin' fender flare holes that come stock on the 73 series fenders. Understand, that this is a 1989 BJ74 but the fenders are obsolete. So I have a 73 series fender, which I guess are far more popular and still available. But that leaves me with a bunch of holes...
  12. cruiserpilot

    BJ74 rear quarter replacement

    Finally got to that cool stage of actual fitting and mocking up to ensure that things will slide together. I then took the ink pen and marked out all the holes for punching and spot welding. I have a crap load of vice grips, and they are the mandatory tool for this kind of stuff. After...
  13. cruiserpilot

    BJ74 rear quarter replacement

    Got this punch and flange combo tool a few years ago. It's quite a cool useful tool. It makes the spot welding a heck of a lot easier!!
  14. cruiserpilot

    BJ74 rear quarter replacement

    So back at it. I've been getting a bit of an idea of how to deal with the lighter 0.23 wire and 18 ga metal. Got the welder dialed in and using lower power but 8-9 ft/min of wire speed and I boosted the gas. So I got to finally rebuilding the lower lips of the outer wheelwell openings. Many...
  15. cruiserpilot

    BJ74 rear quarter replacement

    Yeah, got the taillight housing spot welded in, and 98% of the rest done. I've got to punch the spot weld holes in the new fender and then tack it in. I spent a grotty hour grinding the inner wheel well of useless undercoat and seam sealer. I got to it in the nick of time, one more winter and...
  16. cruiserpilot

    BJ74 rear quarter replacement

    Now I've started the small replacement piece for the outer wheel well at the rear. I'll finish it up tomorrow. There essentially isn't anything behind that. It will be nice and strong anyhow.
  17. cruiserpilot

    BJ74 rear quarter replacement

    I cleaned up the taillight area again, and got that piece in. Had to ensure that its flat at the front so the taillight bucket will fit cleanly.. I have to admit, I'm happy with how this turned out.
  18. cruiserpilot

    BJ74 rear quarter replacement

    Well, got back at it. Finished the front B pillar stuff today. Lots of dicking around, had issues with the welder. Finally sorted that out. I enjoy building these pieces, crude but effective.
  19. cruiserpilot

    BJ74 rear quarter replacement

    I will check your thread. I did get the bits in a 3 pack. I'm done with them now I think. I tried to attach a photo from ipad in the shop but the wifi too weak there. I'll add some pics in a bit. I've got to the make bits now stage. I bought a sheet of 18 ga, and some .023 wire today, and of...
  20. cruiserpilot

    BJ74 rear quarter replacement

    So I cut the bottom of internal bracing and did something that only modern technology can bring. Photo of internal rocker box using the top corner of iPad, backed up with a mini LED headlamp. Not as bad rust wise as I imagined, so I'm gonna brush it out and hit it with some rust paint, then...
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