Builds 1st FJ40, '76 - SMOKEY - Puttin’ her Back Together (5 Viewers)

[Vae Victus]

Decided I have to replace the last 1” of the bed.

 

[Vae Victus]

Finished that up and did the final grind. Crap, forgot I didn’t finish. I really dislike grinding.

I tried to drop the 1” lip down about the thickness of the panel to emulate the offset bend in the original. It was done so the sill cover will fit over it and like up with the bed. This is going to be an issue!

 

[Vae Victus]

Then needed to replace the areas to the left and right side of the bed where the door edges meet the side of the truck. (Goes off to find out what those are called on the CCOT website). Oh, yea, Corner Channels.

 

[Rainman]

What, you have one?

What I meant was, you could've asked me which way it went. I don't know all the answers but I know more than I can remember.

 

[Vae Victus]

exhaust manifold? i'd do that before to much longer even moisture in the air can rust cylinders. keep at it

Reading back through comments. Yikes. That's got me freaked out now.

 

[Vae Victus]

Update:
Been doing lots and lots of body work.

R & L rockers - Done
Read corner channels - done
Rear sill - done
Right Quarter - done
Left quarter - in progress. Stopped to analyze driver door rocker pillar, which has been bashed in previously.

Some pics (I’ll spare my normal level of detail)

 

[Vae Victus]

Removed the door and tire carrier supports on both sides, blasted and primed, ready for welding back in place on the new quarter panels. Took good measurements to locate them properly. (I hope).

One more pic of the first quarter. I’m pretty proud of that welding job. Aside from the runs from my quick spray job to keep it from rusting, it's not bad. Used a damp rag to cool every 4 spot weld group. No warping!

 

[Vae Victus]

Also welded in the frame mounts in the front that I made. Had just bolted them on until I put the body back on the frame.

 

[Vae Victus]

Replaced the edge of the fender well where it meets the driver's quarter panel. It was shot for about 10".

 

[Vae Victus]

Also discovered some damage - the cross member from the front of the tub where it meets the back of the door pillar on the driver's side is pulled away about 1/4".

That should have been a clue to what I found next, the door pillar itself does not line up with the new quarter panel - the door pillar has been bashed in at some point. There was a light layer of bondo hiding some of it, but the panels were not lining up. I removed the bondo to see the damage, and found that the pillar was in about 1/4" where it should have been straight.

Holding off on the quarter panel welding till I get some good advice on what to do (my guess - let the paint guy hide it with bondo as best possible after I clean up the metal a bit to ensure it is solid. That will be the only scar that I didn't replace that they will have to heavily bondo unless i find a donor somehow.).

As you can see in the last photo (barely) I just welded the cross member to the back of the door pillar, matching the other side, since it seemed stable, and the rear quarter did end up fitting just fine.

 

[Vae Victus]

Actually, as I posted in a separate thread asking about this repair, I am going to investigate just replacing this section of the door pillar. It is the worst area and has the most to gain if I replace it.

If I put a straight edge on just the middle portion of the pillar, these 8-10” are really pushed in. Might be enough to make it all be fairly clean.

 

[Vae Victus]

Mark at Mark's Offroad suggested cutting it out, straightening it, and welding it back in. That's brilliant! That's why I ask the crowd for ideas and advice. Actually, this is how my entire truck has been built because I had zero restoration experience when I began this 7 - l o n g - y e a r s - a g o!

So, thanks all you individuals out there for always helping me! Ya'll rock.

 

[Rainman]

Guys. Scott is the fastest learner I believe I may have ever met. Patience and perfectionism. That's a powerful combo. I tip my my hat. (well, I would, if I ever wore one.)

 

[RWBeringer4x4]

Scott this is looking incredible - I’m learning a lot from your body work, so as always I appreciate the thorough descriptions. Really solid work, and encouraging since I’ll be starting my body work (someday) with no meaningful experience as well.

If I keep putting dents in it at the rate I went last summer/fall, I’ll need all the vicarious learning through you I can get...

Glad to see you keeping at it!

 

[Texas Navy]

You and I got our 40s in the same calendar year, but the difference between them now is exceptional. Keep blazing the trail; I am 6ish years behind....amazing work sir.

 

[Pirate323i]

Just read through this whole thread! Great work Vae Victus. I have just got myself an '83 here in NZ and will be heading down the same rabbit hole soon...

 

[Vae Victus]

Just read through this whole thread! Great work Vae Victus. I have just got myself an '83 here in NZ and will be heading down the same rabbit hole soon...

You read the entire thing? Well I guess this is a good time for it! (Corona virus creates some down time for sure!)

 

[Vae Victus]

You and I got our 40s in the same calendar year, but the difference between them now is exceptional. Keep blazing the trail; I am 6ish years behind....amazing work sir.

Thanks TN! After 6 years I figure I’m closer to done than it feels. Still trying to push toward getting to “the next phase” which is paint and assembly of the motor.

 

[djcfj40]

I just finished mine after almost 7 years and flooded four feet deep and torn completely apart twice.
I can tell you that once you get it into paint and start putting it back together you really start to have fun.
Keep pecking away at it and sweat the details. Totally worth it in the end.

 

[Pirate323i]

You read the entire thing? Well I guess this is a good time for it! (Corona virus creates some down time for sure!)

Yep, I was "working from home"...