Build #27 red and white 55, full body restoration.

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Everything is in the bed of my Tundra here. It is now with the sand blaster. Doors, roof, quarters and fenders are still here though. Off to Cruise Moab Wednesday so hopefully when we get back it will all be ready for pickup.

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Everything is sand blasted now. Some remaining rust still needs repair. It was best to wait until after blasting so I could see everything. Most of these small repairs are pretty easy, just time consuming.

This is part of the inner D-pillar, and the bottom is rusted. It has a lip bent along the bottom where it connects to another bracket behind the quarter and sill. It's twisted at different angles but wasn't tough to recreate. I have made the piece and will cut the old piece off, then weld this on.


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There has been so much happening this week on the 55. All of the sandblasted parts are being prepped for epoxy primer and weld-through primer. It takes some planning and masking. Some parts, we are reassembling now and priming the entire piece afterwards. Others, we have masked the long runs of holes to be welded, will spray epoxy first, then remove the tape and spray weld-through primer on the areas to be welded. The majority of these pieces are not visible but wherever you look in this vehicle that isn't painted, it will be white.

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Here is another example of cracks behind the hinge on a pillar. All of the doors were cracked around the hinge and some pillars too. I believe that this cracked due to the location of the spot welds on the bracket that attaches to the back side of the pillar. The spot welds are in the center of the bracket, not really adding the strength because the weld locations were not outside the hinge bolt openings. I drilled some holes on the outer part of the bracket (6 smaller holes on the black piece) that I will weld and it will add more strength. This should stop the piece from cracking in the future. Worn hinge pins and bushings really cause most of these cracks though in my opinion.

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WarDamnEagle said:
That's actually a large part of my rationalization for going through this much trouble and expense. I figure they are all going to rust in, out, top down, or bottom up (or both) unless you do this; it's just a matter of time. Unless perhaps if you can find one that's always been in a desert climate and you plan on keeping it in said climate. I was contemplating chemical dip followed by e coating but you would have to drill a lot of holes to make sure you got all the rust neutralized and full coverage of the e coating. At least this way you can see with two eyes what there is to treat, replace, or just paint.
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This is the most amazing look at Pig anatomy that I have ever seen!
Thank you for making it possible.
 
kelly saad said:
More parts removed. Passenger and driver sides are done. Now for the rear sill and inner rocker pieces.

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Many thanks for taking the time to document your work with pictures and words for the rest of us!

I know it takes extra time.

Your skills and experience are amazing.
 
kelly saad said:
Good idea. I don't have a scanner though, I do everything the old way. I will have some rust repair panels made though. I already have the lower fender pieces made and the DXF file to cut more.
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Files of the rear corners would be nice!
 
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