83 FJ60 Build up thread (1 Viewer)

[Project60]

Frame Repair

Got 1.5 hours on the 60 tonight.

I got more the passenger side frame rail cut out. I almost got the back (behind the rear x-member), but my grinder from HF died... guess it doesn't like 100% duty cycle - that's what $15 buys you ;p.

It took about 10 4.5" cut off wheels to get this far... not too bad. The 3" air grinder was worthless, I think the wheel was too small.

Passenger side frame rail removed:

 

[MutleyFJ62]

nice work, true dedication, you'd think the frame would finish itself, given how nice this is going to end up

 

[Project60]

Frame Repair

Got 1 hour on the 60 tonight. I cut the last piece of inner frame rail out of the passenger side. I finished hanging the tarps too.


Passenger side frame rail, rear:

Tarps Hung:

I put an eye bolt in the middle of the frame so that it would "stand up" on it's own with out having to lean on the work bench:

 

[Project60]

New Angle Grinder

As a side note, I did go and exchange my angle grinder at HF. I had it for less than 30 days and they swapped it out, no problems.

I used the new one tonight for roughly 15-20 minutes and it did the same thing .

I will take it back too, maybe I will try for a different model .

Funny thing is that my last HF angle grinder lasted 2+ years and I only got rid of it because the pin quit holding the head from rotating and I couldn't get the grinding wheels off.

 

[Project60]

Frame Sandblasting

50 min on the 60 this afternoon. I got some sandblasting on the inner frame rails done.


Passenger inner frame rail:

 

[Project60]

Frame Repair

Got 3 hours on the 60 between today and yesterday.

I spent two hours sandblasting the rest of the inner frame rail. Clean up was a pain. Then I got the majority of it inner frame rail tacked into place and some beads laid. Ran out of welding wire though .


Inner frame rail and channels sandblasted:

Inner C-Channels welded/tacked into place:

 

[Project60]

Frame Repair

Got an hour on the 60 last night. I picked up some more welding wire and got about 2-3 inches of bead laid when my welding gas ran out . So I switched sides and spent a little time trying to cut out the driver side inner frame rail.

I ordered up some zero-rust (1 gallon) should be here today. If the weather isn't too bad I should have a finished frame by the 1st of the year . Once this milestone is reached, will tally up the hours and cost so far .

 

[Project60]

Frame Repair

Got 1hr 10 minutes on the 60 today. I got the passenger side inner frame rail welded into place finally. I started grinding on the driver side too.

Got my Zero Rust paint too!

 

[Project60]

Frame Repair

Got 25 minutes on the 60 last night. My cheap HF grinder died yet again when it got too hot... guess you get what you pay for when you want a heavy duty tool.

So I went this morning and bought a new Dewalt (Model D28810) at Home Depot:

 

[Project60]

Frame Repair

Got 10 hours and 10 minutes on the 60 yesterday... Long day.

I finished cutting out the inner frame rail on the driver side. Then drug the frame out into the driveway and spent the day sandblasting... until the hose froze over! Drug the frame back into the garage and welded the inner frame rail back into place.

Pictures to Come...

 

[Chase77]

Inspiring....

 

[Project60]

Frame Repair

Got 2.5 hours on the 60 this afternoon. Finished sandblasting!

Next up is paint.

Still working on the pictures... stay tuned.

 

[Project60]

Frame Repair Pictures

Here are the pictures from the last two days of working...


Driver Side Inner Frame Rail Removed:

Driver Side Inner frame rail, rear section removed:

Driver Side Inner Frame Rail - You can see the rust and the "water line" where the water sat with mud/sand and rusted from the inside out (top of the picture is the bottom of the frame):

 

[Project60]

Frame Repair Pictures

Sandblasting on the driveway (yes, that's snow in the background!):

Frame almost done with sandblasting:

Driver side frame after sandblasting the inside, MUCH better:

 

[Project60]

Frame Repair Pictures

Long section of DS inner frame rail welded back into place:

Rear section of DS inner frame rail welded back into place:

Frame sandblasting complete:

 

[BosBok]

Dude, the lengths you go to! But keep it up, this is awesome work.

 

[Christian]

To the Zen-master-blaster!
You are meticulous! The patience...
You are still galvanizing it right?

 

[Project60]

To the Zen-master-blaster!
You are meticulous! The patience...
You are still galvanizing it right?

I decided against it. The only reason is that the guy at the coating place said that if you don't get all the paint off, the frame won't be galvanized in those spots. The galvanizing process will melt off all the existing paint, but won't coat those areas. Even by splitting the frame rails I wasn't able to get all the paint off the insides.

I figured for $500 it wasn't worth it for where I live (20% humidity most of the year).

 

[Project60]

Frame Repair

Got 1hr 40 minutes on the 60 tonight. I mounted some boards to the frame (top of the frame) using 1/2" x 3" pipe, 3/8" x 1.5" washers and 3/8" lag bolts. I flipped the frame and rested the boards on some saw horses. I then went and sprayed the frame down with Prep Step which is the recommended stuff from Zero Rust.


Make shift paint "booth" in the garage:

Frame mounted to 2x4's to elevate it off the saw horses:

Serial number on frame:

Flash Rust on frame. This only appeared after spraying on the prep step... not sure if I should be worried as it is in only a few spots:

 

[Landcruisin'60]

If its anything like POR-15 it bonds to rust better the bare metal anyway. So I wouldnt worry about it. I thought just swapping a frame was good, you stepped it up a few notches. Looks good! I dont think I would have the patients to do all this work when a frame isnt that much more.

This may be a stupid question, but why didnt you paint the inside frame rails when you had them split? It doesnt look like you can paint them as well now.