Builds 1978 FJ40. Waking up the ol’ girl!

[TCEd]

Wow ! Bold step and you're doing fine. That floor pan is a good place to start and refine the skills set before moving to the outer panels.

 

[EStein]

Wow ! Bold step and you're doing fine. That floor pan is a good place to start and refine the skills set before moving to the outer panels.

Thanks! That’s what I’m hoping...and lots of practice scraps.

 

[EStein]

…..and 9 months later! It’s hard for me to get the time and motivation to post these days and I’ve got painfully slow internet! So I’ve been going to town…I have most of the front floor and outside rockers replaced and am on to the rear tub. I was hoping I could salvage the main beam and mid bed (and I probably could have) but I just decided to replace it all and start fresh with clean metal. The more I dug, the more rust I found. Pretty much replacing all but the top rail! Bought a few parts from Real Steel but most from Cool Cruisers and I’ve been very happy with them. Here’s some pics from the progress so far.

 

[EStein]

Front pans and rockers…

 

[EStein]

Main beam and mid bed…where the three flanges of the floor, main beam, and mid bed comes together, it was pretty rotten in places along that whole seam. That’s the main reason I decided to replace it all..

 

[EStein]

After cutting out the rear floor, I realized how bad the frame braces and spring perches were…I’d been hoping it would go away but it was keeping me up at night. Picked up the biggest air hammer at Harbor Freight and went to work cutting rivets. Assembled it back together with bolts then welded the threads…not stock looking unfortunately but they’ll hold. Got the perches painted up and nice and then remembered that this get welded to the frame. Burned most the paint off. Ha. Oh well. Can’t remember where I got these parts…maybe eBay. I will look if anyone interested.

 

[EStein]

Got the quarters cut off and now mocking up all the pieces. This is going to be challenging. I plan on getting it all set with clamps and sheet metal screws and get the top and doors on before doing any welding…..sooo, now I’m caught up! What I haven’t shown is all the major challenges I had, parts I tried to fab or salvage but gave up and bought new…I’ll try to keep with the posts as I go…it’s hard after the fact!View attachment 2880328View attachment 2880329

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[EStein]

 

[65swb45]

Bionic, absolutely bionic Eric!

 

[Drake2]

View attachment 2880347View attachment 2880349View attachment 2880350

Great progress! Better be careful, if you keep up that great work I may send mine your way

 

[EStein]

Bionic, absolutely bionic Eric!

Thanks Mark! It’s been exactly what I need this last year. So frustrating at times but one of the most rewarding things I’ve done!

 

[EStein]

Great progress! Better be careful, if you keep up that great work I may send mine your way

Oh man! So glad you’re in Wisconsin! I actually do think of getting another…maybe one that doesn’t require quite so much work. I have to keep this one for my daughter. She’s got a bunch of time invested as well.

 

[65swb45]

Thanks Mark! It’s been exactly what I need this last year. So frustrating at times but one of the most rewarding things I’ve done!

When you do a good job, it makes you smile every time you look at it. That is the essence of the empowerment this forum provides.

 

[EStein]

When you do a good job, it makes you smile every time you look at it. That is the essence of the empowerment this forum provides.

Excellent! Happy New Year Everybody!

 

[DirtDauberGarage]

Awesome job!!!!!!

 

[EStein]

Started tacking the quarter panels in. Just the bare minimum to hold it just in case I have to take it apart. Also using sheet metal screws in spots for now. Messed with the rear sill for hours. It’s still off a bit. Whole thing needs to slide toward the drivers side about 1/2 an inch as you can see in the pics. Hoping I can elongate the body mount holes while it’s in place, then slide it. I think I’ll put the top back on this week to make sure it all fits before doing any more welding. The sheet metal screw trick is a great idea I stole from someone. Turn them into plug welds when it’s all square.

Also my daughter went to work with the wire wheel and paint on the last bit of frame I hadn’t had access to. She’s home from school for another couple weeks. It’s good she likes the jobs I hate.

 

[EStein]

Was able to get the top on and everything lined up today. I was pleasantly surprised that the doors fit so well. I was really careful keeping the original pieces square when cutting but also going to chalk it up to a bit of beginners luck. Either way I’ll take it. Almost looks like I’m making some good progress… Had to remind myself that the top is going to require some rust repair and all four doors are going to need new bottoms. Then there’s prep and paint which I know nothing about if it’s not in a rattle can. Still hoping to have it on the road this summer. That’s my goal.

 

[EStein]

Been plugging away. So much to weld and grind. I’ve been stitch welding about every 6 inches all the way around. Then the rear sill. Hammer and put some compressed air on…..then start again. I’m really worried about heat and warping so it’s taken a couple days so far. Happy with the results for the most part. It hasn’t been without struggles getting it all to fit. The bed was about 1 1/2 inches too short so had to add some metal at the rear sill. It’ll work though. I keep telling myself this will never be concourse. Actually laid in the bed for an hour tonight listening to music. First time it all felt pretty solid. A really good feeling!

 

[EStein]

So here’s a little issue I have. The wheel wells aren’t even with the floor/upper sill. It’s about 1/2 inch off front to back. Not sure where It went wrong. Everything lines up…I don’t think it’s going to cause any problems besides bugging me….if you have an idea let me know. They’re only screwed in with self tapping screws at this point.

 

[EStein]

Also you can see it’s a bit off here…can’t figure out why. The bottom lip of the floor lines up perfectly with the bottom of the wheel well side….if that makes sense. So if you raise or lower the wheel well, then it doesn’t match the floor. Thought maybe it sagged in the middle when I cut out the rockers and main beam but the side doors line up pretty good. Oh well.