83 FJ60 Build up thread (1 Viewer)

[Project60]

Body Work

I got 3hrs on the 60 between last night and tonight. I got the passenger side quarter panel patch almost completed (>95%). Looks good and went waaaaay quicker than the driver side.


Passenger Side Quarter Panel:

 

[Project60]

Body Work

I got 4hr 15min on the 60 this weekend. I got the passenger side quarter panel all finished up. I started on the inside of wheel well and under the rear floor.

I am moving along, but bodywork is not a quick thing.

Sorry no pics as the wife had the camera for the day. I'll get some pics up later this week.

 

[Project60]

Body Work

I got 6hr and 5min on the 60 over the last few nights. I really had to cut out the corner of the rear sill... lots of destruction. I got most of it put back together.

Finally got some pics too!


Rear Quarter panel done (needs some smoothing! ):

Inside of rear quarter panel with patch welded into lower portion:

Corner of rear sill almost completely cut out:

Rear corner going back together:

As far as I got tonight:

 

[Project60]

Body Work

Got 2hr 30min over the weekend on the 60. I got the rear sill finished up, a patched welded into the wheel well, and the drip rail welded onto the passenger front A-pillar (didn't finish from a long time ago).


Wheel Well patched up:

Rear sill/corner all finished up:

 

[Project60]

Body Work

I got 3hr 25min on the 60 over the last three nights. I got the inner wheel well on the passenger side finished. I used two patches from the donor and had to make a 3rd piece. I love welding upside down!


Passenger Inner Wheel Well Finished:

Miscellaneous Spots ground down and prepped for sandblast:

 

[philos1]

every time I look at this thread I shed a tear for your mountain of effort...

keep up the stellar work man.

 

[Project60]

every time I look at this thread I shed a tear for your mountain of effort...

keep up the stellar work man.

Thanks!

 

[Project60]

Body Work

Got 1hr on the 60 tonight. I figured I better do some tech, so I decided to do a step by step of how to put a patch panel in. I got two more patches welded into the passenger side, rear internal quarter panel.


First I cut a template out of paper:

I cut a patch out of 18 gauge mild steel (4'x8' sheet) using a 3" cut wheel:

After cutting out, I "bend" to shape using my poor man's brake. You can see this limits the size of my patch :

I tack the patch into place using pliers/clamps to hold it:

Then I fully weld the patch(es) into place. No, I didn't add the ribbed feature. Yes, I know... it is weaker without the ribs. But solid steel with no ribs is stronger than steel with holes in it :

Then I use a flap disk on a 4 1/2" grinder. Best is 60 grit.

The flap disk sands the welds flat without grinding through the existing metal. I didn't sand them completely flush here as no one will see this area and it does take considerable time:

 

[klinetime574]

You are amazing. Totally awesome work going on here.

 

[Project60]

Body Work

Got 2.5hrs on the 60 over the last few nights. More body work for now.

I welded up the snake blinder holes on the passenger side and flap disked flat:

I got the last patch put into the passenger side wheel well - before:

After:

I also got the last patch put into the inside of the inner quarter panel on the passenger side (I'm holding the old piece):

 

[flybynight]

I know it has been said but the amount and quality of work you are doing (while learning as you go!) is very admireable(sp?).

 

[Project60]

Thanks for the compliments guys!

 

[Project60]

Body Work

I got 3hr and 45 min on the 60 over the past few nights. I got the passenger side rear seat bracket area fixed (in the wheel well) and started cleaning up the rear floor to re-installation.


Rear seat bracket secondary brace:

Rear seat bracket inside:

Rear floor bracing before cleanup:

 

[SKINNER]

Looking good man!

I know it's late to offer, but you don't need anymore patches for the rear do you? I still have the scabbed 1/4's left that have some good sheetmetal left. I'm done with them, so let me know if there's anything you need (I think there are pics of them in my thread).

Keep up the good work!

 

[Project60]

Looking good man!

I know it's late to offer, but you don't need anymore patches for the rear do you? I still have the scabbed 1/4's left that have some good sheetmetal left. I'm done with them, so let me know if there's anything you need (I think there are pics of them in my thread).

Keep up the good work!

Thanks for the offer SKINNER, but I actually got my quarters all done!

 

[Project60]

Body Work

I got 1hr and 30 minutes on the 60 tonight. I got the rear floor supports all cleaned up and tacked into place. It is starting to come back together!


Rear floor supports cleaned, primed with weldable primer and tacked back into place:

 

[kling-on]

WOW nice work

 

[Project60]

Body Work

I got 4hr and 30min on the 60 over the last few days. I got the floor supports welded in and I almost finished prepping the outer pieces of rear floor... they were trashed.

The biggest pain was the ribs in the floor, they aren't perfect but at least they don't have holes!

I can almost see the light at the end of the sheetmetal tunnel!!!


Passenger side floor w/ rusted spots cut off:

Passenger side floor patched:

Driver side floor w/ rusted spots cut off. The picture shows one rusted spot still attached:

Driver side almost done (last patch still needs welding in):

 

[Project60]

Body Work

I got 3hr and 50min on the 60 over the last few days. I finished welding in the outer floor pieces and started prepping the main piece of the rear floor. I have found that using a 4.5" wire wheel to go over the floor parts to remove the undercoating works best. First I remove the undercoating, then use the flap disks. If I hit the undercoating with a flap disk, it gums up and is almostly instantly ruined.


Driver side installed:

Passenger side installed:

Seat belt brackets removed and sandblasted at work:

Rear floor with undercoating removed:

 

[Project60]

Body Work

I got 9.5hrs on the 60 over the last few days. I got my new exhaust fan vent installed (fan works MUCH better now). I also got the floor patched, prepped and almost halfway welded back into place. I thought it took awhile to drill the spot welds out... you should see welding them all shut!


Fan vent installed (used to be 2 6" dryer vents, now 14" x 18"):

Seat brackets welded into position:

Floor patched on both sides:

Floor about halfway welded into place: