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  1. cruising4trbl

    Sill Cover Replacement - 1977 FJ40

    Yes, the trick is to prevent moisture from getting there. I honestly wonder how possible that is though. As a friend once said, the only thing that’s water proof is a box with a hole in it. In other words, give the moisture a way to pass through, get aired out. But idk I’m just trying to get...
  2. cruising4trbl

    Sill Cover Replacement - 1977 FJ40

    My appetite for repairing rust has more to with my weekly pain threshold than the actual rust on the vehicle.
  3. cruising4trbl

    Sill Cover Replacement - 1977 FJ40

    Yep, I did. It turned out great.
  4. cruising4trbl

    Sill Cover Replacement - 1977 FJ40

    nice! What year is yours? Mine is a 77 and has the little step on the edge. I ended up reconstructing the bad parts of the cross bar then welding on the sill replacment.
  5. cruising4trbl

    Sill Cover Replacement - 1977 FJ40

    My '77 40 seems to have rusted first on the sill piece. I believe it was left in the rain and just sat like that for two decades. The PO did not drive this vehicle for about 25 years. For this reason, there's little to zero corrosion underneath the vehicle. There's also no corrosion on the...
  6. cruising4trbl

    Sill Cover Replacement - 1977 FJ40

    More pics. Again, I removed the sill cover. This is the exposed cross member. I cut out the cancer already.
  7. cruising4trbl

    Sill Cover Replacement - 1977 FJ40

    Here’s what it looked like before.
  8. cruising4trbl

    Sill Cover Replacement - 1977 FJ40

    So to start, I’m new to sheet metal work but have done small part fab before. Trying to tackle some of this on my own. As far as I can tell, the sill cross member behind the round side of the quarter panel has little to no rust. After tearing off the sill cover, I found rust on the top of the...
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