#11 Dune Beige bodywork and paint 40 series

[kelly saad]

FYI, This is labeled "11" because the other 10 are in the 60 forum. New to the 40 section here, so this is the first.

The project:

1. Disassemble vehicle, remove doors, top, fenders, and windshield.
2. Strip entire vehicle to bare metal.
3. Remove rear tub half. Disassemble and rebuild.
4. New quarter panels and any rusted sections of inner fenders. Likely will make new inner fenders.
5. Fabricate all new braces under rear tub section, and any other parts that are unavailable.
6. Sand blast remaining rust, treat bare metal with POR-15 Metal Prep and/or Zinc primer.
7. Exterior paint, B/C, wet sand, and polish.
8. Assemble.

 

[kelly saad]

Its rusty. The previous paint job had bubbles in the body filler everywhere. They coated 1/2" thick fiberglass filler over all the rust, and that was fun to remove.

 

[kelly saad]

Disassembly of all the rear panels. Some can possibly be sand blasted and reused. I will most likely make all new parts for this. The inner fenders are in bad condition and I would rather make new ones than patch up the old. Also, the braces on the underneath side of the rear floor too, I will make new ones. Upside down in the picture below.

 

[Graniteone]

Right on!

 

[franklin40]

if only i lived closer! i didn’t know you were doing 40s!!

 

[Pierps]

Man, that first picture goes to show how nice a rusty rig can look with a carefully chosen camera angle!

Looking good, man! lots of work ahead of you, but it looks like you know what you're doing. Good luck

 

[kelly saad]

if only i lived closer! i didn’t know you were doing 40s!!

Haha! Neither did I

 

[kelly saad]

Some progress photos. This has taken far too long, but I have been slammed trying to get caught up. Its about to get exciting though

 

[Graniteone]

Woohoo!

 

[kelly saad]

I need to update this thread, it's been a while.

All new tub parts were purchased. This rear sill support piece I had to make because we couldn't find a new one. The old one was too rusty to repair. Not the prettiest thing I have built but its buried under the tub.

 

[kelly saad]

After fitting all the tub pieces and getting that figured out, I realized the quarters were 1/2" too long. So, I had to cut them back.

 

[kelly saad]

So, now I have the tub ready after test fitting everything. I have prepped the underneath side for epoxy primer and seam sealer. I am still woking on the jump seat brackets though. They were in bad shape, but I soaked them in acid for 2 days.

 

[kelly saad]

Also, These door jamb pieces needed to be cleaned up. I sand blasted them and stripped all the existing coatings off. One side was beat up, so I cut the outer part off and rebuilt it.

 

[kelly saad]

This vehicle had a second fuel tank, however the quarters only had the single fuel door opening. So we ordered a second fuel door and housing, but I needed to fabricate the opening with the rolled lip in the quarter like this one in the photo below.

 

[kelly saad]

I decided to bend 2 pieces and use the stretcher to get the correct radius for the corners. Then, trim them to fit the door, and weld them together.

 

[kelly saad]

Next, I need to cut and opening in the quarter where the previous gas door was located and install this.

 

[kelly saad]

This turned out very nice. No body filler needed.

 

[kelly saad]

The rear of the tub where the sill meets the quarters had a seam on each side. After I welded them together, I decided to use lead here, and not body filler.

 

[Greek Cruiserhead]

Looking mighty fine, man. Thanks for sharing, keep it up!

PS. May I ask where did you purchase your new body panels?

 

[RevISK]

Sweet.
Hope to see more.