1976 FJ40 Build Up/Resto Thread

[Nomis]

Anyone know of a good seam sealer? I need to pick some up at some point.

Edit: Looks like 3M has a brushable seam sealer. Should have it at NAPA.

 

[Nomis]

Got the hood back from the sandblaster - looks good with only a few spots towards the front that will need attention. My rear sill came in from CCOT just before the holiday weekend and I must say that I'm impressed with the quality, fit and finish so far. I will have more to report once I fit it and weld it in place. Here's a pic of the sill as delivered, both the inner structural piece (black) and the cap are 16 guage and have all of the OEM bolt holes for tire carrier, body mounts - as well as the indentation and captive nuts for the amby door striker. This is exactly what I was looking for.

 

[Nomis]

Rear Deck

Had to replace a small portion of the rear deck along the edge that will join up under the rear sill:

 

[Nomis]

Got some more work done - pax side corner needed a new inner and out channel piece:

1) Old cut out
2) New inner
3) New corner channel

 

[Nomis]

Next up were the rear body mounts. I tore up the old ones upon removal for the most part. I flattened out an old mount to use as a template. The new mounts are 16 guage and are held in with a larger 12mm shank / 19mm head bolt. For the rubber - I used 1/4" reinforced truck bed material.

 

[paranoid56]

very nice mounts. i like the ways those came out. might have to use that idea on mine

Shane

 

[Nomis]

Sill is fitted up. Just waiting on rear driver's side quarter to come in from Iron Pig. Once I get that I should be able to wrap things up back there.
Here's a shot of the sill in place and the fabbed up mounts in place:

 

[tlcruiser66]

Good idea on the body mounts, i'll have to remember that.

Looking good so far, keep it up

 

[HeavyLift]

nice handy work....keep it up

 

[rabid]

cool mount idea. Looks great.

Cool story on the rig as well.

 

[Nomis]

Sill finished - now on to the quarters.

 

[Nomis]

Rear right quarter in place. Had to fab up lower patch panel to cover what the replacement quarter didn't cover. Also used 3M Brushable seam sealer on the back side of the quarters where water and mud tend to collect - this should help to inhibit rust from forming back there in the future:

 

[Nomis]

Fitted up left quarter which took a fair amount of measuring and trimming until it was just right. Then drilled out holes in the quarter to enable spot welds. While working on that side I found the mounting location for an old CB antenna - probably going to weld up those holes as well as I have no need for them. Also, the hole below the parking light hole is where I will need to fab up another patch - saw some rust developing in there and just as soon put in new metal.

 

[Nomis]

Rebuilt the hinges - had to have the pins pushed out by a local NAPA machine shop. Used new bushing from SOR, now they are good as new. And another shot of the rear with sill and quarters welded in - still need to grind down the spot welds. I will be removing the brace structure soon.

 

[Nomis]

Had to remove a few broken bolts that held the hard top to the upper rail. This bolt extractor from Craftsman did the trick. I first drilled through the bolt and to my surprise the bolt began to move with the drill bit - almost unscrewed completely. I would have been screwed if that happened as it would have dropped inside the frame rail - which is now sealed because the new quarters are in. Luckily it was still hanging on by a few threads and the extractor backed it out without issue thankfully. I was relieved as I had visions of having to cut into a good quarter just to get the bolt out as I didn't want it to be rolling around making clunking noises at every stop light - but it worked out in the end - and it made my day.

 

[Nomis]

I ordered up some new tail light gaskets and lenses and decided to clean up the housings while I was at it. The chrome light refractors cleaned up nicely with some metal polish. I also used a silver paint on the rest of the internal housing. I used a black enamel from rustoleum on the exterior of the housings. I've got the OEM metal tail light guards that will be installed as well when the lights go in.

 

[cruiserjunktion]

nice work Nomis!

 

[Nomis]

nice work Nomis!

Thanks Mel. Hope all is well up there in Gainesville.

 

[subzali]

So how much welding experience do you have? Thinking of having to do something similar to my truck this summer/fall - what you've done so far doesn't look like it's been too hard, but the end result is great!

 

[UNO_RACING]

You're making great progress!