76 FJ 40 rot where front and rear tub meet and more (1 Viewer)

[PghMike]

Where the front and rear tub meet a box that runs the width of the truck and incorporates 2 body mounts. The front lip appears to have good metal. The rear floor is rotted at this seam . The 3rd piece that incorporates the body mount is rusted especially on the drivers side.

I am looking for photos of what others have done to repair this. I have some ideas but previous experience on a specific repair is valuable. I can weld and fabricate so I'm not looking to do scab patches.

Thank you

 

[PghMike]

Cut out the rot , fabbed up a 1x2 tube for the body mounts. Working on removing the remnants of the old metal. Will make new pieces to box it back in.

 

[pb4ugo]

I sloppily cut out the main channel from the bottom. Then i was going to use something jeep cj bumper C channel and add gussets. In my search for a bumper, a friend offered to make/break some real thick sheet and made piece of C channel. I capped the ends and added gussets. I bolted top of it to the tub using the seat mounting towers holes and the frame mounts on the bottom. Pardon the crappy pic.

 

[PghMike]

More progress

 

[HeavyD]

Looking good Mike!

 

[PghMike]

Test fit now to prep for welding.

 

[PghMike]

Ready to weld.

 

[pb4ugo]

Looks good. I was going to do the repair that way, but decided to use the C channel and leave the cavity open so I could hose it out.

 

[PghMike]

Looks good. I was going to do the repair that way, but decided to use the C channel and leave the cavity open so I could hose it out.

I am going to use cavity wax to spray inside periodically.

 

[PghMike]

All welds are done. Dress up a few welds then seam sealer and paint with Chassis Saver. On to the rockers.

 

[PghMike]

More progress. Painted the edges of the quarter panels and door frame for pre installation prep.

 

[PghMike]

To save time I decided to replace the wheel wells both tops and sides. They are repairable but just too much effort would be put in and they would still have issues. Time is money. Hopefully the rear quarters will be tacked in place by Wednesday.

 

[kudzugypsy]

thats impressive to be doing that with the tub on the frame - i know from my own experience with this same issue. my floorpans were toast so they had to come out. crawling under the truck i could see massive rust in those seams so the only solution was to cut.
when i got the midbed side cut out the channel was FULL of dirt - 50 years worth - it sits in that channel wet and rots the point where 3 pieces come together, its a perfect rust breeding area. you have the channel support, the mid-bed and the floorpans all attaching right there.

 

[PghMike]

I am using seam sealer and going to apply cavity wax yearly.

 

[PghMike]

Daily update. Quarter panel fits. Welding and finishing the rocker first . It will be easier to block sand and maintain the seam between the rocker/ Quarter panel. Be careful Welding on your cruiser, this old metal burns through quicker than the patch panels.

 

[PghMike]

Cut the drivers side wheel well out to repair the bed. New wheel well components will be here tomorrow. No school on Friday but I brought the old wheel well home to cut out the old supports to reuse. I am hoping to have the wheel wells and quarter panels tacked in place by the end of next week.

 

[PghMike]

Rear sill and white top.

 

[PghMike]

Completed rear sil I built. I bought the sheet metal portion.

 

[PghMike]

Passenger side quarter panel tacked in place. Dr side bolted and tacked to the sill. Wheel wells , trying to fit them in place. They seem to need some adjustments before spot welding in place.

 

[PghMike]

Lots of stuff done today. Top rail on drivers side trimmed and tacked in place. Wheel well top and sides spot welded together. Temp installed top to check for alignment of doors quarter panels and Wheel wells .