Build 1978 FJ40. Waking up the ol’ girl!

[EStein]

For those of you that weld badly like myself… You’ll appreciate these photos. I had a frustrating day welding. Mainly because of my bad cuts resulting in my gaps too wide but I really struggled getting these door patches fitted. Possibly getting burned out and not taking the time I should. I hurt all over from welding and grinding all day. Some of these blow through holes were pretty big, and I eventually got them filled but huge gobs of weld, which means huge amounts of grinding…. i’m in a bad mood.

 

[EStein]

Part of the reason the cuts look so bad is because I wasn’t very careful keeping the front panel straight and once I got everything welded together, I noticed a huge bow in the door so I had to go back with the cut off wheel and cut the back panel so I could pound it back flat again. I started getting frustrated and sloppy. Anyway, I think it’s all gonna turn out OK in the end, but it probably isn’t going to be as good as I would’ve liked.

I did screw a straight edge horizontally along the door to try to keep it flat, but I didn’t think about vertically…

 

[RevISK]

How much prep are you doing on the metal? Degreasing? Looks like you’re leaving a decent amount of paint too. What are you doing to cool off your welds?

I’ll assume you’re keeping your tip clean? Using 0.23 wire?

I’m no “Wizard” by any stretch but if I get lax in prep, I spend far more time fixing my BS than if I would’ve just done it in the first place.

At least you’re getting after it, that’s what counts. It’s going to be awesome.

 

[aztoyman]

These days are the ones we learn the most from. Next time will be better because of it.

Extra work and frustration but it will still look good.

NOBODY got good at something by doing it perfectly the first time. Just doesn't work that way.

 

[EStein]

How much prep are you doing on the metal? Degreasing? Looks like you’re leaving a decent amount of paint too. What are you doing to cool off your welds?

I’ll assume you’re keeping your tip clean? Using 0.23 wire?

I’m no “Wizard” by any stretch but if I get lax in prep, I spend far more time fixing my BS than if I would’ve just done it in the first place.

At least you’re getting after it, that’s what counts. It’s going to be awesome.

Haha. Well…..30 wire, dirty tip, didn’t degrease,
I did sand the epoxy off along the edges…mostly. Cooling with compressed air but I know I’m going too fast. I probably should have taken the day off but yes, it will be awesome. I can’t wait till the done phase so I can just drive and tinker! I tell my wife “never again” each time I come in from a long day in the shop. Just these darn doors to go!

 

[EStein]

These days are the ones we learn the most from. Next time will be better because of it.

Extra work and frustration but it will still look good.

NOBODY got good at something by doing it perfectly the first time. Just doesn't work that way.

So true! Thanks!

 

[RevISK]

F’ing prep (or lack thereof) will get you every time. It’s why I despise painting so much…

My door patch is janky because I let it get too hot, oil canned on either side of the seam. I’m hoping a shrinking disc will help when I get to the point of, “well, I’d better fix all my learning mistakes”…

 

[EStein]

F’ing prep (or lack thereof) will get you every time. It’s why I despise painting so much…

My door patch is janky because I let it get too hot, oil canned on either side of the seam. I’m hoping a shrinking disc will help when I get to the point of, “well, I’d better fix all my learning mistakes”…

Yeah can’t say I’ve enjoyed the body stuff although I get tons of satisfaction after the fact. I’ve got the dreaded oil canning as well. I’ll look up shrinking disk…I know I’m going to feel like someone took one to my spine when I get out of bed in the morning.

 

[EStein]

Continuing on with the doors…rear doors turned out pretty good and I’m pleased with the fit. Lots of grinding today! At one point I went a little too far and ground through the metal and had to cut another patch for the patch. Ugh! Haha.

This is irritating. I’m not sure why I rounded this off. Earlier I figured I would just deal with it but after looking at these photos, it’s gonna bug me so I think I’m going to have to add a little piece on there.

 

[EStein]

The drivers door is turning out to be a big pain. There’s a pretty prominent bridge along my weld line. Not sure how to deal with that. Whether it’s a shrinker disc that was mentioned in an earlier post or maybe a torch or just pound the heck out of it? I posed the question to the experts on the main forum. Anyway, it’s disappointing.

If I can offer some advice to anyone that is doing what I’m doing, don’t use the whole patch if you don’t need to. Cut it down and only replace as much as you need and maybe you can keep the weld line closer to the bend at the bottom of the door. I think that being a little more rigid might solve the issues. I did that with the second door, and it seems to be going better.

Passenger door is going to turn out better. Cut it off a lot closer to the bottom.

 

[RevISK]

That is essentially what happened with my driver side door. Too much heat applied to the weld line causing it to expand and pushing the neighboring panels inward. In my case it happened more on the grinding down of the weld than the weld itself (door was used in a tv commercial for harbor freight, of all places. Director wanted “more sparks!!!” For far too long. The talent was an actual fabricator and kept saying, “this door is going to oil can if I keep going”… the director’s wife is who gave me the truck so…). Got the patch for free and got paid to weld it on. It sure was nice before all that.

I’ve looked into shrinking discs, torches and dry ice and bracing. Your advice to only weld what you need is very sound. Also, GO SLOW.

 

[RevISK]

Relooking at your photos, localized heat and a planishing hammer might be your answer.

 

[EStein]

Relooking at your photos, localized heat and a planishing hammer might be your answer.

I posted on the main forum as well. So far the consensus is re-cut clamp, and re-weld. Pretty sure I overheated on the grinding. Wasn’t even thinking about that. I’m so impatient. I feel like if I get too crazy I’m going to be looking for a new door.

 

[RevISK]

Yeah, I didn’t want to say that might be the best option.
Thinner wire will go a long way to helping, as will a bit of patience.

You’ll get it.

 

[EStein]

fast forwarding a bit… I ended up cutting out that bad weld on the door and replacing the whole panel below the door handle. A lot of work, but it ended up much better! Light coating of Bondo. Epoxy primer, sealed and sprayed color today. I think it’ll all be OK. Again… Don’t look too close.

 

[EStein]

Prime and paint

 

[RevISK]

Looks great!

 

[EStein]

Couldn’t wait to see how the doors looked on the rig… Got the rear doors loosely hung. I need to find a good write up or video on how to reinstall all the internals. I took all the latch assemblies and windows out in a hurry and didn’t really pay too much attention. Anyway, I think they look great! Getting close!

 

[aztoyman]

They look awesome and NO rust.

 

[EStein]

They look awesome and NO rust.

Yes!!