Nice welding work David, where did you get your auto dark helmet? and how much$??
83 FJ60 Build up thread (1 Viewer)
- Thread starter Project60
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- Thread starter
- #362
I got the helmet for $39 at Harbor Freight. Here is the link to the coupon that expired yesterday
- Crazy CouponsIt's on sale right now for $49 until 5/27, but I found the coupon on the web... I just googled "Harbor Freight Coupon" and all kinds came up.
Hey! nice work. nothing left untouched here.
I have some plans to change some pieces on my HJ60 this summer so i was wondering:
When you drill out the spotwelds, do the layers separate easily, or do you have to chisel them apart either way?
I have some plans to change some pieces on my HJ60 this summer so i was wondering:
When you drill out the spotwelds, do the layers separate easily, or do you have to chisel them apart either way?
- Thread starter
- #364
Cowl Repair
Got 1 hour on the 60 tonight. I got the other side of the cowl repaired (where I butchered it). I am getting better! It's not done, but is going much quicker now.
Before:
Now:
Got 1 hour on the 60 tonight. I got the other side of the cowl repaired (where I butchered it). I am getting better! It's not done, but is going much quicker now.
Before:
Now:
- Thread starter
- #365
If the layers aren't rusted together too bad, the top layer will just come off once all the spot welds are removed. If they are rusted together, they come apart pretty easy with a chisel or air hammer - you may have to "massage" them back into shape when you are done.
- Thread starter
- #366
Rear Floor Removal
Got 50 minutes the other night drilling out spot welds on the rear floor... only 100 more to go. I did that as I had run out of welding gas. I did upsize from a 20cf tank to a 92cf tank ... Now I need a welding cart .
Got 50 minutes the other night drilling out spot welds on the rear floor... only 100 more to go
. I did that as I had run out of welding gas. I did upsize from a 20cf tank to a 92cf tank ... Now I need a welding cart .
- Thread starter
- #367
Cowl Repair
Sorry for the lack of updates. I have been working this week, but haven't posted. I got 5hr and 35 minutes total in this week.
I finally got the cowl finished up! It took some learning to do the sheet metal. You have to get it hot enough to get penetration, but cold enough not to simply blow a hole. I also found that a 60grit flap disk works well on grinding down the welds. If you use anything more severe, it makes the surronding metal thin and it will blow through on the next spot weld.
Welded up all the holes on the firewall where the spot weld removal bit went all the way through. I used a copper pipe smashed down as a backer plate:
Here is the hole in the firewall I patched up. I just hammered it flat and welded it shut:
Here you can see where the spot weld cutter went through both sheets. I have outlined where I want to cut and made a paper template:
Piece welded in:
Another Example; before:
After:
I also removed the hinge supports for the hood from the cowl, they had surface rust too:
Pile of cowl parts ready for blasting and epoxy primer:
Sorry for the lack of updates. I have been working this week, but haven't posted. I got 5hr and 35 minutes total in this week.
I finally got the cowl finished up! It took some learning to do the sheet metal. You have to get it hot enough to get penetration, but cold enough not to simply blow a hole. I also found that a 60grit flap disk works well on grinding down the welds. If you use anything more severe, it makes the surronding metal thin and it will blow through on the next spot weld.
Welded up all the holes on the firewall where the spot weld removal bit went all the way through. I used a copper pipe smashed down as a backer plate:
Here is the hole in the firewall I patched up. I just hammered it flat and welded it shut:
Here you can see where the spot weld cutter went through both sheets. I have outlined where I want to cut and made a paper template:
Piece welded in:
Another Example; before:
After:
I also removed the hinge supports for the hood from the cowl, they had surface rust too:
Pile of cowl parts ready for blasting and epoxy primer:
- Thread starter
- #368
Driver Side Drip Rail
Got 1hr 45 min on the 60 tonight. I got the driver side drip rail removed, cleaned up and epoxy primered. I drilled out the spot welds and then cut the drip rail just above the driver door. I had to sand/grind all the paint and rust off. Then I shot a coat of epoxy primer on the A-pillar and the drip rail.
Sorry no pics... Wife has the camer this weekend.
I got a new welding cart and put it together too! Much nice getting it off the floor.
Got 1hr 45 min on the 60 tonight. I got the driver side drip rail removed, cleaned up and epoxy primered. I drilled out the spot welds and then cut the drip rail just above the driver door. I had to sand/grind all the paint and rust off. Then I shot a coat of epoxy primer on the A-pillar and the drip rail.
Sorry no pics... Wife has the camer this weekend
.I got a new welding cart and put it together too! Much nice getting it off the floor.
- Thread starter
- #369
A-Pillar Repair
Got 2hr 45min on the 60 today. I started by removing the passenger side A-pillar (don't worry, its only the outer shell). I got one of the 3 patch panels welded into place. I also kept going on removing the rear floor. Every time I find more spot welds, I find more pieces to remove and rust to repair .
Sorry, no pics tonight!
Got 2hr 45min on the 60 today. I started by removing the passenger side A-pillar (don't worry, its only the outer shell
). I got one of the 3 patch panels welded into place. I also kept going on removing the rear floor. Every time I find more spot welds, I find more pieces to remove and rust to repair .Sorry, no pics tonight!
- Thread starter
- #370
Body Work
Got about 3hr 10 minutes on the 60 today. I finished up the drip rail on the driver side (epoxy primer was finally dry enough). I also worked some more on the passenger side A-pillar. And in between welding, I kept plugging away at the rear floor.
Driver side drip rail finished:
Passenger side A-Pillar cut out:
Passenger side A-pillar almost complete:
Rear Floor (all those shiny spots are spot welds I have had to cut out):
You can see the rear wheel wells where the seat brackets are... ugly!
Got about 3hr 10 minutes on the 60 today. I finished up the drip rail on the driver side (epoxy primer was finally dry enough). I also worked some more on the passenger side A-pillar. And in between welding, I kept plugging away at the rear floor
.Driver side drip rail finished:
Passenger side A-Pillar cut out:
Passenger side A-pillar almost complete:
Rear Floor (all those shiny spots are spot welds I have had to cut out
):
You can see the rear wheel wells where the seat brackets are... ugly!
Looking good man, how are you sealing inside your A-pillars and panels to prevent future rust?
- Thread starter
- #372
I am going to shoot Epoxy Primer on the inside them weld them back together. I think I am going to drill a hole on the inside when I am done and spray some more primer inside using a tube. When I am completely done painting, I will spray a little oil inside.
I can't think of a better way right now... I know the welding burns some of the primer off, but it will last at least another 10 years.
- Thread starter
- #373
Rear Floor Removal
Got 45 minutes on the 60 tonight and got the rear floor out
. What a pain.
Sorry, the wife is taking the camera, so no pics for a week or so!
Got 45 minutes on the 60 tonight and got the rear floor out
. What a pain.Sorry, the wife is taking the camera, so no pics for a week or so!
- Thread starter
- #374
Body Work
Got 2hr 20min between last night and tonight. I finished the patches on the passenger side A-pillar. I also got more the rear floor removed. I am about done removing the floor... any more and I don't think it will hold up well.
Sorry... no pics until next week.
Got 2hr 20min between last night and tonight. I finished the patches on the passenger side A-pillar. I also got more the rear floor removed. I am about done removing the floor... any more and I don't think it will hold up well.
Sorry... no pics until next week.
- Thread starter
- #375
Body Work
Got an hour in today on the 60. I sandblasted some brackets and the inside of the passenger A-pillar. I came home tonight and shot two coats of epoxy primer on those parts. After a few days, I can weld the A-pillar back on.
Sorry... still no pics.
Got an hour in today on the 60. I sandblasted some brackets and the inside of the passenger A-pillar. I came home tonight and shot two coats of epoxy primer on those parts. After a few days, I can weld the A-pillar back on.
Sorry... still no pics
.
- Joined
- May 30, 2008
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Great Thread, Thanks for taking the time to do it.
What an absolutely awesome thread. I have been debating this same job with fortunately alot less rust on the body.
My main goal is the like new frame and suspension.
Again thanks, I will be checking back daily to gather the balls to tackle this same job.
My main goal is the like new frame and suspension.
Again thanks, I will be checking back daily to gather the balls to tackle this same job.
- Thread starter
- #378
Thanks guys! I just keep trying to plug away at it! Remember, this is a first for me... so I am learning as I go too.
- Thread starter
- #379
Body Work
Got 1hr 50 minutes on the 60 today. I got the rear floor supports removed... yuck, talk about dirty. I also started patching holes and welding in a 3" x 4" patch in the driver side quart panel.
Sorry, still no pics!
Got 1hr 50 minutes on the 60 today. I got the rear floor supports removed... yuck, talk about dirty. I also started patching holes and welding in a 3" x 4" patch in the driver side quart panel.
Sorry, still no pics!
good to see you are still going on the project. take your time don't get ovewhelmed and enjoy it. thanks for keeping us updated.
clint
clint
