Builds 79 Aussie BJ55 build (1 Viewer)

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Some more welding and rust mitigation work
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Got some more progress..

some holes to weld in from the other side
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top angle welded on and cleaned up
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Drain holes
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rounded corner to try and mate up with the existing metal work.
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And the body ready with primer for final welding in.
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Tonight I'll get some fish oil in behind the inner A pillar, B pillar and rear wheel wells which will be inaccessible after replacing the sill..
 
I'm by no means a "welder" but I have borrowed a MIG from a work mate (I had been warned off attempting this work with a ARC welder), and have an idea on what makes a good/bad weld and I'm just 'having a go'. I recognise my patch isn't the best but the welding on the slider is sufficient and am more than happy that will be stout enough for a few years.. :) I've been working with the replacement bulkhead/firewall patching up holes and rust spots and this has been more practise with the MIG. All good, I'm just happy to be making some progress..
 
Not to high jack the thread but any good suggestions on a welder pm me with good brands. Don't want to weld for a job just hobby and pig love.

Back to the piggy you are making grest progress looking very good.
 
Got some more done..

I like that the sill is almost level with the chassis..
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compared my xyz measurements which were spot on and burnt in the A B and C pillars.
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I have done afew tac welds on the other side but forgot to clean up the weld area so need to do that before i can complete that side.
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feel free to pass judgement on my welds. i think i'm getting the hang of dialing it in better and after fudging the lower bit on the a pillar join things started to come good..

top part of this seems ok
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hoping theres enough heat/penetration in those welds
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Floor removed
So its been a while since last update but i have been getting a little bit of time to spend in the shed...

For those purists, please look away now..

Got the other sill replaced,
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cut out the floor..
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then the firewall
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With most the the stuff cut OUT and no longer in the way it was time to get stuff IN to see how it would all come together..
so the cowl went in.. this will be my reference point as the firewall, a pillars and floor all come from this point. Everything ties together so I cant really elongate or alter it too much.. I've only had to make the cowl in 10-20mm each side to fit in there..
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Then the firewall gets mocked up.. this will mean the front body mounts need some tweaking to use the factory holes in the BJ73 floor..
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Then the floor is put in place. this lets me see the seat mounts and how it sits with the sills (its just resting there no at the correct height yet).
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Then the bit behind the front seats, 2nd row foot well.. this has a bracket underneath so it doesnt sit flat.. it'll also need a bit of massaging as it has a rise in the center..

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Things are still ticking along here.. I've got a deadline now with a camping trip booked in in August in Victoria, our ferry booked, holidays taken and accomadation paid for so i'm under the gun to get things done..

Work has settled down and I got a bonus for the effort which allowed me to return my mates welder and buy one of my own..
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So far I've managed to weld in some 1.6mm sheet to the factory A pillar panels. In the process patching more rust.
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Weld the firewall to the floor and seam seal it, also painted sound deadener on the floor.
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I've finished off the cowl and welded a firewall upper in-fill
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Seam sealled the A pillars at the door hinge access
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Welded some additional sheet to make up the gap in the floor for the 2nd row
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Using the BJ73 body mounts to support the floor at the seatbelt bolts. I need to weld these up but they are spaced correctly from the chassis now
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Trimmed up the 75x75 angle to support the floor
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completed a test fit with clutch and brake pedals, steering column. These bolt up to the cowl AND firewall and need to confirm correct positioning of everything before going forward
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And lastly the BJ73 front body mounts need to be extended lightly and raised to use factory BJ73 floor holes
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Looks like you’re starting to get the hang of that new welder, nice work!!
 

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