Build 1979 FJ40 Old School Overhaul

[oldschool4wheeling]

Welded up holes along top of windshield frame. Some of them I drilled when I put on my bikini top.

And some the P.O. drilled, but they are on the inside of the frame, not the outside... hmmm

 

[oldschool4wheeling]

Also mount my roll ball. Drilled more holes and welded on captive nut.

 

[Rainman]

Go Doorgie, Go!

 

[oldschool4wheeling]

Go Doorgie, Go!

I'm on a tear Rainey!! I got a list of things that I still needed to do, getting shorter.

Still to do this week:

1. Cut out rust on floor boards and replace

2. Cut out channel on underside of running boards and replace

3. Cut out rust on rear fender tops and replace

4. Plug weld antenna holes

5. Finish disassembling front clip, DS fender, DS apron, Bib

Next week

1. Find sand blaster

2. Find painter

3. Get paint codes from PPG for 621 Rustic Green and Cygnus White (If it is cygnus white on 79)

4. Get paint codes for gray interior --- Roll bar, seat frames ( Im wondering if it is the same for grey Steelies)

5. Find upholstery for seats

 

[oldschool4wheeling]

Hole holes holes and more holes... Im not counting... but here are 10 more

 

[oldschool4wheeling]

Drilling more holes, making more backing plates, more welding... ahhh now I can mount my jump seat.

 

[gator25]

Looks great man.

 

[oldschool4wheeling]

Didn't get much done today... working on my rig 6 days straight has exhausted me.

I did finish removing DS fender, apron and bib.

Only broke 1 bolt!!

 

[oldschool4wheeling]

I also took the time to remove, what I call "black mammie," of the floor board. I used a torch and putty knife. Wheww... mega PITA!!

Then cleaned it up with 92 octane!! ( It was all the gas I had...)

After getting them clean, I figured out my attack.

 

[oldschool4wheeling]

Here are my patch panels... I decided it wasn't prudent to put in the whole thing. Most of my floor boards are good, except along the edge of the rocker.

So with that being said, I'm cutting out part of floor pan and parts inside and outside of rocker panel.

 

[Rainman]

Under the circumstances, take a little break. You don't want to get burned out... or burn bridges...

 

[adistler1]

Here are my patch panels... I decided it wasn't prudent to put in the whole thing. Most of my floor boards are good, expect along the edge of the rocker.

So with that being said, I'm cutting out part of floor pan and parts inside and outside of rocker panel.
View attachment 1493103
View attachment 1493111

You're a machine!

 

[oldschool4wheeling]

Under the circumstances, take a little break. You don't want to get burned out... or burn bridges...

You're a machine!

Thanks guys!!

I had a little Dr. Dinky's Medicated Eye Wash tonight. My aches and pains are almost all gone.

 

[Varty Yo]

Wow 6 straight days on the cruiser!!!

I wish i could get 6 straight hours to work on mine... sigh #dadlife

 

[MOTOV8R]

Wow 6 straight days on the cruiser!!!

I wish i could get 6 straight hours to work on mine... sigh #dadlife

Exactly! I was finally able to get 2 hrs in yesterday on mine after 4 weeks of neglect.

 

[Vae Victus]

I also took the time to remove, what I call "black mammie," of the floor board. I used a torch and putty knife. Wheww... mega PITA!!

Then cleaned it up with 92 octane!! ( It was all the gas I had...)

After getting them clean, I figured out my attack.

Oh man, I hated removing that black soundproofing stuff. BUT I wish we had access to it to put it back down - I bet it would stop a whole lot of sound and heat. Plus, the metal underneath was PRISTINE.

Used a hammer and chisel, chipped off pretty easily.

 

[oldschool4wheeling]

BUT I wish we had access to it to put it back down - I bet it would stop a whole lot of sound and heat. Plus, the metal underneath was PRISTINE.

I was thinking the same thing, wish I had some to put back down after I get done fixing everything.

 

[Trailortrash]

All of these was on the inside my side panel...

How do you stop the rust on the inside???

I'm figuring that is a bout $500 worth of rusted metal.
View attachment 1491294

I poured a bunch of ospho in my rear doors and hatch (I have a 73) and shook them. Also did it to my pillars as rust was pouring out of one side during pressure washing. I don't know if it's the right thing to do but I don't know how to slow the rust down in the interior of said pieces.

 

[oldschool4wheeling]

I poured a bunch of ospho in my rear doors and hatch (I have a 73) and shook them.

Im thinking along same lines...

I was also thinking I would put my rig on a special diet... you know when I change my engine oil I would spray the seams and under carriage with Kroil or maybe diesel fuel. I think that should be part of the maintenance schedule....

The Owners Manual should have stated:

"Maintain body every 3000 miles or 30 days depending on driving conditions. "

"Removing all grit, grim, dirt, mud, and salt from all parts".

"Then use 3.8 liters / 1 gallon with 50/50 mixture diesel fuel and automatic transmission fluid. "

"Spray along the entire underside of the body. Paying special attention to front fender braces, lap joints, rear sill and quarter panel seam, rear fender brace seams, front floor board seams, rocker panel seams, front bib and along the whole inside of the frame"

Im sure the tree people wouldn't mind.

 

[oldschool4wheeling]

Trying to go slow... and not cut out more than I need to.

Trying also figure out how to best attack my floor boards and rockers.

Here are some pics.. BECAUSE OF THE RUST, I can't find all the spot welds the inside seam and because I sanded some on the outside I can't find all of those spot welds.

This has greatly increased the PITA factor.