'75 frame off...4 years and finally starting

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Joined
Mar 1, 2008
Threads
3
Messages
21
Location
Dayton/Bellbrook/Xenia Ohio
I think it about time to start a build thread. I have been checking out the progress that many of you other guys have made. I have stolen about all the ideas I need and now it about time to give back.
This build thread will be spread over a long time, as it has taken me a long time to get to this point.
Let me start with some background. I have had a few SUV’s before this FJ40. I had a 78 K-5 Blazer, an 85 Jeep Cherokee and a 96 LX450. I still have the LX450. My wife didn’t like the Jeep Cherokee and wanted a Safari. I convinced her that the FJ40 was better so we got one.
I found it in a newspaper ad. A guy up interstate 75 spent his winters in Arizona searching for cruisers and shipping them back to Ohio. Mine is a’75 with an earlier hatch and double bottom doors in the rear. It has the original 2F with a factory PTO winch. It ran great and had very little rust for a 25 year old rig. My thought was just to get a good one and drive it. It also, as I found out, had very little paint left on the underside after the years of sun and sand in the desert.

In the summer of 2004 I found a car lift for my garage. This created an additional parking space. The LX450 being newer, and the two 84 300ZX (One my wife’s DD and the other my race car) had spots and the poor cruiser had been odd man out. In the process of packing the cruiser in the garage I discovered that sitting out in Ohio winters didn’t agree with the unpainted underside…it had been completely eaten up with rust. I stepped in the back and went through the floor. Time to tear it down and restore it.

I am not new to restoring cars as I had rebuilt my race Z , have a 63 TR-3 under my belt and have a 67 Austin Healey in the body shop.
The tear down was completed in short order. The frame was sent out to be sand blasted and primed. The tub stored until I could get it in a hot tank to be stripped. The rest of the parts were photographed, bagged and stored away in the garage and wood shop.
That was late 2005 and early 2006. At that point the frame rested up against the wall in the front of the garage and was forgotten.
Fast Forward to 2009. I had blown the engine in my race car and while getting frustrated with the lack of progress on getting it rebuilt (it will be ready for this season) and while waiting for the Obama stimulus bill to kick in and get me back to work, I pulled the Cruiser frame into the shop and started to work.
As I said in the beginning this will be an extended project, so if you don’t hear from me for awhile, please, someone ask where I am, sort of kick me in the butt so I keep going.
I know how much you all like pictures so here are a few. I will have a few more as I repair the frame.
I can’t believe that I only have one digital picture of the cruiser before I tore it down.
Here are a few of the pictures during the tear down.


Pictures:
Landcruiser.webp
Frame rear.webp
Frame and wheels.webp
 
It should be illegal to take southern rigs north to the rust belt!! :)
 
Wow - that frames got the cancer real bad - hope its not terminal
 
Start of fixing rusted places

First I got some parts from Cruiser Solutions to fix the rear cross bracing and the rear spring gussets. Then I started looking at the bad places in the frame. I had several places that needed attention. All of them are on the inside “C” channel and mainly on the passenger side, except on the rear where it was both sides.
Frame restoration 017.webp
Frame restoration 021.webp
Frame restoration 022.webp
 
Cutting rear sections out

I searched the MUD site for information on fixing the frame. Most of the reference was to find a new frame as the cheapest way. That was fine, but finding a good frame in Ohio would be hard and shipping one from California would be expensive. Then I found this thread: https://forum.ih8mud.com/60-series-wagons/128847-83-fj60-build-up-thread-6.html
This got me going. I started on the rear two sections. I cut them out
Frame restoration 023.webp
Frame restoration 024.webp
 
Weld edges and check fit

Then welded on some 1 ½” x 1/8” steel for the returns into the frame. After two days of work I had two of the patches done. Now I will weld or bolt them in place. I am leaning toward welding. If I do that I will weld the seams all along the frame. If I bolt them, then I could paint it and then assemble the frame. I know that either way has its
champions.
Frame restoration 033.webp
Frame restoration 038.webp
Frame restoration 034.webp
 
New direction: easier way to make a patch

I was about to start on the next section and I had a thought. I couldn’t find any patch pieces anywhere and it was going to take me days to make the other 3 patches. So I made a pattern of the entire inside frame. This took me a couple of days.
Frame restoration patch panels 001 (Small).webp
Frame restoration patch panels 002 (Small).webp
Frame restoration patch panels 003 (Small).webp
 
Metal patch peices arrive for approval

Google is your friend. I googled laser cutting and found a local company that would undertake a small project. It turns out that they do automobile parts and have done some for heeps. Now they have done some for Landcruisers.
I picked them up this morning. Just have to go through and verify that the joints and holes are where I want them so they can adjust the program as needed.

There are nine separate patch pieces. These are done as mirror images where I could so I had to have 6 separate pieces done. This kept the cost down both in programming them into the laser and ordering. The numbers are determined by how many you can get out of a quarter sheet of material.
Frame restoration patch panels 012 (Small).webp
Frame restoration patch panels 004 (Small).webp
Frame restoration patch panels 008 (Small).webp
 
Wow. That cruiser would surely have been lost if it wasn't for your efforts!

:clap:

:beer:
 
:eek:Crap, those Ohio winters were tough on the old girl!


That's what your baby is going to look like in about 10 years after it makes its' way to the Mistake by the Lake.
 
Very good job on the frame patches and ideas. Looks like you have a solid start on your build. Thanks for the hint about using Google to find laser cutters. That tip will come in handy. Keep up the good work.
 
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