There are probably better threads out there than anything I’m going to document but I thought it might be worth something to share my work. I’m not an experienced welder or body guy so this will be the average (or below average) joes body job. There’s a couple of threads from 2013 for this truck where a shop in Liberia called No Lemon did major rust repair on the lower windshield and cowl and also some frame patching. I knew I had to take action when the lower right fender mount tab rusted off and started rattling. The running board was already removed due to the rust in the inner rocker. Finally got the right inner and outer fender off. Still have to disassemble the front clip to remove the fender apron. There is rust through the firewall that was obscured by the apron. The tabs that mount the apron to the fender lip rusted off and one of the previous owners decided to weld the apron to the fender. The scope of the repairs for this project will include removing as much of the outer rocker as I can so I can easily access the inner for patches, replacing as much of the outer rocker as I can easily with a piece from a new one, patching firewall and floor pan, repairing fender connecting tabs all around on the fender as well as the apron, and patching other various holes I’m sure I will run into. Parts I know I will need include a new outer rocker, which I ordered today, new fender nuts, a new mudflap, and some sheet metal bits and bobs. I’ve got a decent set of tools though no brakes or benders. There will be lots to learn.
1986 Lj70 Rust Repair (2 Viewers)
- Thread starter richmason
- Start date
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- Thread starter
- #2
This is probably well known by most but I learned taking this apart that the fender comes off before the apron. The apron slides over the front frame/body horn and can’t be removed without taking off the entire front sheet metal with the radiator fan shroud, grill, headlight frames, etc. I will post pics of that when I have it off. Here are the rockers in their current state. I have a small amount of rust in the door frame (I’m sure there is more once I start grinding it). There’s weird rust in the front edge of the door that I’ll deal with as well. Still need to pull interior out so I can document current status.
- Thread starter
- #3
The biggest challenge I ran into having rustoration work done in Liberia 12 years ago was the unavailability of quality preservation and rust proofing chemicals. I brought as many Eastwood products as I could in my luggage but it often wasn’t enough. Part of this job will be to treat areas that didn’t get protected properly in that previous work. In the windshield corner photo you can see where whatever wipe on body shutz they used was put on over rust and didn’t stick, probably because we ran out of rust converter.
- Thread starter
- #4
As you can see in the pic, the fender has multiple issues. I’d love to buy a new one and a new apron, which are available, but that’s out of my budget for this beater. If anyone has a pic of the inside lower corner that has rusted away, I’d appreciate seeing what’s missing. Also, if anyone can share the dimensions of the fender lip or just a good photo, that would be helpful as well. The drivers side is in much better shape in those areas so I can use it as a model for some of this. I’d rather not remove it to see if the lower corner bracing is the same. Thanks!
My build thread has some pics. I’m not sure exactly what spot(s) you are looking at, but I have both my front fenders off at the moment. I might be able to get some more detailed pics for you late tomorrow. Tell me some more detail and I’ll see what I can get you.
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- #8
Thanks LRDF. I need to restore the original bolt holes and overall fender lip and the outer edge of the apron where they connect. I also need to restore the lowest part of the fender where it attaches to the body. Pictures and measurements of either of these would be fantastic.
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- #9
More progress today. I found a great YouTube video that shows this exact job on a short wheelbase 70. He fabricated all of the parts while I’m taking the path of less resistance with new metal from Toyota. I hit a bit of a discouraging point today. The metal that attaches the tub to the rockers is rusted higher up than the rocker line. Looks like I will need to cut into the rear fender apron, which has already been patched on my truck, in order to get access. Another few hours of cutting and then I can turn my mind to how I’m going to rebuild the tub attachment flange piece. It won’t be nearly as elegant as in that video series!
@richmason - I’ve direct messaged you the pics.
- Thread starter
- #11
Major cutting is done. Got the tub to rocker piece off. It’s much worse than in that video. Fingers crossed my local machinist friend will make it for me. Not sure I can justify bead roller and stretcher shrinker for this job.
- Thread starter
- #12
I think I’m making progress. Following that video I dove into metal shaping and welded the resulting piece to the car. It’s not a perfect match but it will hopefully do. My welding penetration is terrible but it will hopefully improve as I go along. New inner rocker arrived so today’s project is drilling out spot welds in pan to inner rocker connection. Floor pan sits on top of 90 degree flange on top of inner rocker.
- Thread starter
- #13
Old panel out! New one looks good! Have to repair rust in floor pan before I can actually weld rocker in place since they weld together where there is missing metal. Also need to reweld a small tab that attaches firewall on lower corner. Otherwise ready to grind paint and plug weld the old spots.
jblueridge
SILVER Star
Repairs look great!
