I think you have those part numbers backwards. 56121-60110 shows up for HDJs while McGeorge shows me 56121-60100 for my '94 US-model.
The groove must be for the chrome (?) trim around the windshield:
Just as a point of reference, with my tread *just* covered by the fender and a little sidewall stickout, I've never picked up a rock chip from my tires. I drive and park in a gravel lot almost every day. That's with Nokian Rotiiva HT tires. Maybe you'll get more rocks flung from the edge with...
Interesting. I've got 265/75-16s on stock aluminum rims, and no flares. The tread is *just* hidden by the fender. The sidewall sticks out. I've got a "2.5 inch" OME lift that was more like 3", at least when I first installed it. Until I welded on an extension for my rear panhard bracket...
Two stage just means a base for color and then clear coat. It gives a deeper gloss than single stage.
All paint (including clear) oxidizes over time and gets contaminated (e.g. bird poop) and needs to be polished to strip the damaged layer.
Also, all paint also should be coated with something...
I'd suggest looking at T449 Cadet Blue, 6H9 Grayish Green, and 416 Dune Beige. T12 Cygnus White might be a nice alternative to 045 white. I'm partial to older Toyota colors, but that might go completely against your aesthetic preference.
And I, too, think you'd be crazy to do a black roof...
One of the most shocking things in this entire thread is how pristine the paint is on the inner sides of that truck. I can't even keep the paint on my bumpers in good shape, and here they are tossing scrap steel in there!
Oh, and as for *why* brazing, it's probably because it puts less heat into the panel. Since it's two pieces of sheet metal butted together, it's probably more susceptible to warping than the overlapped gutter, and right at a spot where it would be obvious.
From what I've read, the problem...
I'm not sure what the official title is, since I only have a PDF copy and there's no cover page, but the folder is named "1994 Land Cruiser Collision Repair Manual".
Edit: the circles inside the black squares are listed as "spot weld or MIG plug weld".