Builds 1979 FJ40 Old School Overhaul (2 Viewers)

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The first body part I tackled was the rear sill. I ordered a CCOT rear sill and I like the way it installed.
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I looked inside fender well to "guess" where I was going to make my cuts.
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And I zeroed in on the spot welds across the back and drilled them out.
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Then I remove the rear body bolts and bushings....after a day of soaking in Kroil oil. And it came off just like I had done this before....(which I have never done before!!)
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Sorry I didn't get any pics of the installation, but it is straight forward.

At this point the rear body bolts and bushings are holding the sill in alignment. EDIT: I also tacked it to the bed pan.

Which will allow for removal of the quarters.

I did put a 1" angle iron across the back to keep things in alignment .
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Noooo, I have not cut the quarter yet.
I meticulously clamped the new quarter panel over the old. Once I had it fitting like a glove, I got an accurate measurement and marks. I used new fender as a guide for my cuts.

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I would like to say I used a couple of wooden blocks to "beat this fender" into submission. What Im trying to say is that I had to drive the fender from the rear, forward, so that there were no gaps in the curve on the corner. Making sure it was tight made for more accuracy. I also hammered the fender up as tight as possible from the bottom. It had good lines in the rear and at the rocker. :deadhorse::deadhorse::deadhorse: Sounds like I beating a dead horse.... but well you know. :smokin::smokin::smokin::smokin::smokin:
 
Also had spot welds along the front of the quarters panel at the "B" pillar.
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Vanity shot of my borrowed welder ....thanks @Vae Victus
Also had to drill out spot welds on back brace that the spare tire carrier mounted to.
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I began to notice the seam sealer the factory used and at this point I began to see how this thing was built/assembled
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:beer::beer:Nice work!! Excited to see how the fender turns out. The rear sill looks great. Your floor is a little better off than mine.

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The pile of cords and tools everywhere looks very familiar. What did you use to cut the fender out? That blue pneumatic reciprocating saw?

Thanks Motorv8r.

I bought some air tools but I don't have enough air compressor to run them.

So basically I'm using a cut off wheel on my electric Dewalt 4 inch grinder. And I'm using flapper disc on my other electric grinder. They both are working great!!

I try to draw a straight line and use a steady hand. I did use a piece of angle iron as my guide, but I think a steady hand is the key. And of course making sure you cut the line or leave the line.
 
I made my copper plate using 3/4 copper pipe. It definitely helps.
And where did you get that idea?

And yea, I think that you need to grind the weld area clean for that light wire....

Great job - nice to see you posting some of your progress!! It helps us all.
 
Thanks Motorv8r.

I bought some air tools but I don't have enough air compressor to run them.

So basically I'm using a cut off wheel on my electric Dewalt 4 inch grinder. And I'm using flapper disc on my other electric grinder. They both are working great!!

I try to draw a straight line and use a steady hand. I did use a piece of angle iron as my guide, but I think a steady hand is the key. And of course making sure you cut the line or leave the line.

I use a grinder with a cut off wheel as well. Was hoping there was a cleaner less noisy solution.
 
And where did you get that idea?

And yea, I think that you need to grind the weld area clean for that light wire....

Great job - nice to see you posting some of your progress!! It helps us all.

Hahaha, huh...you:hmm::hmm:??? You can have credit... but I m sure I didn't come up with it...
Fixed it for ya!

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Man, I might have missed a spot. :p

Nice!! That's not a :banana:
job:hillbilly:...it's nice to have some tech savvy friends!! You'll have to let me on your secrets on how to make those red circles and pointed lines:hillbilly::hillbilly::hillbilly:.
 
Here is the installation of the new fender. Once again, I BEAT it into submission to make a tight fit. Clamps and more Clamps.

I installed it for the second time after I cut out the old, made my marks took it out, trimmed the new quarter it to fit then reinstalled for the third time.
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I used this piece of wood to align the quarter at the back. Then I installed my little clamps the hold the quarter and then I work the quarter towards the front to get my marks to cut new quarter.

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Notice how long my quarter is...I had to trim off this amount to make for good fit.
 

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