1987 HJ61, rust issues and new paint job

[blis]

Did some more work today, also was going to paint the epoxy primer on left hand side but I ran out of shielding gas before finishing welding and also found that my paint gun was gunked up...

Lift-Up door is off

What was under the first sheet metal of the roof

Another view "under the hood"

After removing the rust with angle grinder and steel wire disk I put some anti-rust primer on the sheet metal

Hopefully work will continue on tuesday when I will get new bottle of argon for the MIG...

 

[slowandsteady BJ]

Are you using "weld through primer?" I hope so. Just saying..... I'd hate to see all that work rust from the inside again.

I gotta say I LOVE the decals. That fading orange stripe is sweet. Reminds me of that old Hotwheels bronco from the 80's!

 

[Doug384]

I'd like to see how you are dealing with the drip rail at the roof's edge. Like yours my 60 has major rust at the roof edge all around, from the front doors around the back lift gate. There is little to work with. I have another 60 with a good roof, drip edge and windows that I am tempted to cut free from it's body to graft onto this one at the pillars. It looks easier than trying to fabricate a drip rail from the pieces needed to be welded in. The other option would be to eliminate the drip rail for the smooth modern look or do no weldng at all but repair it in place with epoxy resin and glass. Any opinions based on experience?

 

[blis]

I'd like to see how you are dealing with the drip rail at the roof's edge. Like yours my 60 has major rust at the roof edge all around, from the front doors around the back lift gate. There is little to work with. I have another 60 with a good roof, drip edge and windows that I am tempted to cut free from it's body to graft onto this one at the pillars. It looks easier than trying to fabricate a drip rail from the pieces needed to be welded in. The other option would be to eliminate the drip rail for the smooth modern look or do no weldng at all but repair it in place with epoxy resin and glass. Any opinions based on experience?

I did some thinking on that part myself but it become rather clear and simple once I actually opened up the roof... Since my fabrication possibilites are somewhat limited (I dont have proper sheet metal tools for bending/cutting) I decided to ignore the drip rail and just be content with fixing the holes on actual roof...

Here is a quick picture (done with paint ) about the construction of the roof. Left side is the original construction and right side how I will do mine...

Originally the drip rail is just tacked onto the chassis, roof comes on top of it and all the seams are sealed with car sealant... With some grinding, hammer and chisel the drip rail comes off rather easily (especially if the rust is bad), I also had some pre-bent sheet metal which after some grinding, cutting and bending fit nicely on the edge of the roof... Will get a picture of the rear section today...

 

[blis]

Some more pics showing the patches made to roof...

Rear section

Right side

On the latter pic you can see the space under the patch that will be sealed with car sealant (I'm using dinitrol 410 I believe)

 

[Doug384]

Your work is looking good. Can you give me a closer view picture? Do you plan to put the original stainless trim on or do you have something else in mind?

 

[markthemenace]

There are actually few reasons for that which I'm gonna list here just for you

1) this car will be seeing occasional offroading, therefore the increased rock-resistance of the skirts will be appreciated
2) I don't want to make bondo/fiberglass patches in this car
3) replacing the skirt with steel bar is in my opinion a lot easier than trying to bend and tack proper sheet metal parts to replace them

That steel bar there does look good! Good luck with your build!

 

[blis]

Your work is looking good. Can you give me a closer view picture? Do you plan to put the original stainless trim on or do you have something else in mind?

My plan was to scrap the original trim becouse I feel it only increases corrosion around the edge of the roof and just leave the lip of the roof as is... I was also planning on removing the old sealant around the rim and replacing it with new one as I go on...


Better pics coming tomorrow hopefully...

 

[blis]

Today was a good day, finished the welding of passenger side, ground down the welds, finished the patch for the rear section of the roof... Old man was on sealant duty... As a finisher I sprayed epoxy primer on the passenger side of the car...

big patch on the rear section

Joining the roof patch to old section

rear section of the roof ground down

some sealant shots

Epoxy primer on

 

[hj 60]

Good to see it can be done in a few days, it takes me about three years

 

[blis]

Spent today working on passenger side doors and rear doors... Got most of them done and primered, tomorrow I will hopefully start working on the driver side of the car....

Patched passenger side door

Another shot from the inside

 

[blis]

Got a lot done today, hopefully by sunday I will get to spray primer on the rest of car...

Second rocker plugged, looks watertight to me

tacked up

welded

Close-up of the front end of the rocker

Best tool ever for removing rust, paint, bondo and other stuff from the car

Rear wheel well was shot up pretty badly....

Original sheet metal on right side, patch on left side...

Tacked on place

Edge curve bent

Welded

Finished, not bad considering my sheet metal tools consist of hand-cutter, hammer, angle grinder and pliers

 

[Pacer]

Killin it! You are making this look easy, thanks for sharing.

 

[blis]

Fixed the rest of rear wheel arc and patched couple holes in the frame today... Tomorrow rest of glasses are coming off (windshield and rear side window) after which I will sand the old paint and apply the primer to chassis...


The hole

Patch for the rear wheel well

Welded and bent

 

[Eric Winkworth]

Looking good man!

Once ur done, oil the truck really well and when thats done oil it again!

Oil is the only reason my DD is still a vehicle!

 

[blis]

Pooh, did an 10 hour day today... But then again, I managed to finish the welding and sanding and also applied primer to rest of the car and doors... Pretty good day all in all with the expection that I broke the windshield when removing it (the windshield was already pretty bad) so I will have to replace the windshield before this project can be called finished...

Drivers side door...

Another patch for the door

Patch on the frame...

 

[maat]

 

[blis]

Well, I managed to spray the chassis today with 2-component acrylic paint (RAL6020 I believe is the color). Nothing much to tell about it expect It seems that theres plenty of dripping and obviously the surface isnt perfect. Then again, in daily driver I value function over looks....

Will take some pics tomorrow, also tomorrow I'm planning on painting the doors and hatches, after which assembly of the car will begin...

I would say the this project is 90% done

 

[maat]

pics!!!!!!¡!!

 

[blis]

Everything has been painted, sprayed some bedliner into rear section of car. Also installed the broken windshield (got quote for new one installed, 188e purty cheap) and rear windows.... Some crappy pics below...

Bedliner

Drivers side (partial)

It's a friggin snow storm (had to move car out of the garage so I had enough room to paint rest of the doors and hatches)