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

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I’m also sad seeing how much rust is hiding in a pig that looks soooo much better than mine 😕

I knew mine wasn't rust free, but it was so much worse than I had planned for. Sand blasting revealed so many sins.
Toyota landcruiser: made durable. Not well. 🤣

And I say that being completely in love with these stupid vehicles.
 
This is the repair piece I made. You can see that the distance is wider where it will attach both sides together. It's about 5" now, so that will help strengthen the door in this location. Where the overlapping metal is shown here, I use a weld-through zinc primer before I weld the pieces together.

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Fantastic! I am going to pour another cup o' coffee and read here.
 
These inner rocker pieces are not straight as they appear to be. The height is about 5 7/8" and at about 37" they angle down and end at 5 1/2" tall. Still, a simple piece to recreate.

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These plasma cuts are where I had to cut through a weld that was attaching the quarters to the sill.The quarters are overlapping the sill where they were welded on. I was going to weld these cuts back together and clean this whole thing up. There are bad pits in the jamb area that will require a good amount of filler and in a difficult area to be sanding.

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So I changed my direction. I decided to make a new one. I made a test piece first to make sure I could make all these bends. It looked good so I moved forward (picture attached). The problem is that my brake is not wide enough. So, I marked everything out, then cut it in half. Next, I bent everything carefully, hoping I was good enough to bend both parts precisely.

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New piece is done. I welded it together and both pieces matched perfectly. All the openings are cut in the correct locations. I welded the bracket on the backside and the small metal piece on the front. I did make that little piece thicker because I noticed the original was bent a little. The gap in between is the same though.

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