Builds 1990 FJ62 "weekender" poptop build (1 Viewer)

[sfcruiser]

I decided to build this back in 2008.

The rain gutters had rust problems. The PO had made repairs. In the excitement of getting my first LandCruiser. I overlooked the small bubbles in the paint. Over time things got worse. I considered selling it and taking a loss.

2011 I decided to proceed .
This project has been great fun. I learned a lot, spent a ton of hours, and as little $$ as possible.

I still have a bunch of stuff to do
this is what it looks like today (9/9/2013)

 

[sfcruiser]

I created a pic of what I wanted the top to look like.

 

[sfcruiser]

I used unistrut as a jig with USPS boxes to cut the roof radius

 

[sfcruiser]

after several attempts
decided to use a rectangular 2x2 sq tube for the base

 

[sfcruiser]

After testing fitting the base frame, making sure it was in between the rain gutters. I decided to cut the roof out. My wife was the fire watch, we had 6 fire extinguisher handy.

I learned that I should've used a cutting saw instead of a plasma cutter. I also should've covered the windows to protect from the sparks. oh well

 

[LAMBCRUSHER]

GOOD MAN! I almost pmmed ya to light a fire under your threatened build threads arse Keep em coming!

 

[LAMBCRUSHER]

I Have been looking at the lift/stay design of the earlier VW campers and have decided that they would do great for when I do a pop top on the wifes 62. Bravo for the commitment! What kind of hinge did you use and could you post pics?...I was thinking of cutting out the whole roof and leave the support in the middle; make the bed plat able to slide fore or aft and access bed thru either the cargo zone or the front seats. Are you gunna do a bed on the bench across from the kitchen, or up in the pent house?

 

[sfcruiser]

After aligning the frame. It was tacked to the body where the cross sections touched. The interior sides were installed first. Stitch welded, 4 points, top and bottom of frame, top lip of body and where ever it was 3/16 or less on the inside of the body. I made 10 - 20 tacks everyday after work. I made them in a criss cross fashion. trying to limit the effect of heat. I don't have a shot of this portion completed but every stitch touched. A nice way to unwind from a busy day.

 

[sfcruiser]

Next, the front and rear panels were welded in

 

[sfcruiser]

The base frame with cross sections weighed in at 40lbs.
The outside side plates weighed in at 40lbs each, before being trimmed to fit.
Like everything else, the sides were stitched in over time. The sides were welded to the top frame and the base everywhere it touched the body.

 

[sfcruiser]

correction, the side plates weighed in at 22lbs prior to being trimmed.

base - 40
2 sides - 40
interior sides - 20
front and back - 20

ball park total base weights - 160lbs

 

[sfcruiser]

sides trimmed out and stitched in

 

[sfcruiser]

Once all the welds were grinded and sanded. I proceeded to make the top.
purchased 3"x 3/16's aluminum angle
sheet of aluminum diamond plate
2x3 al sq tubbing 1/8
2x3 al channel 3/16

 

[sfcruiser]

The aluminum diamond plate was nice, a little heavy. The frame was drilled, tapped and screwed together. This was time consuming.

 

[sfcruiser]

I used SS piano hinge, predrilled every 2". Both the base and top were drilled and tapped.

 

[sfcruiser]

piano hinge

 

[sfcruiser]

I decided to use 3M nidacore instead of the aluminum. An expensive choice. The nidacore was secured with screws. first I had the nidacore on top the frame. I changed it to sandwich inbetween the 3x3 angle and the sq tubing and channel (front). I'm still trying to work this out. I used 75# gas struts to hold top up.

 

[sfcruiser]

We sanded the entire rig to prep for Monstaliner. I used 3M marie flexible epoxy resin from the inside out. Basically covering the welded portions from the inside the rig. The metal was prepped with silver bullet from eastwood

 

[sfcruiser]

monstaliner'd
the side window cracked during the build, minor set back

 

[sfcruiser]

Hinged front, reversed tapped on the aluminum channel. the hinge point is below the top of the 2" sq tubbing.

The rear is just resting on the frame. The fit is good, a little off as you can see. I dont have the exact weight of the top.