84 FJ60 Resto,

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I know these are the ultimate poser pics, but I flexed out the 60 last night to measure for shocks. Unfortunately, I had already bought BRAND NEW Toyota shocks....but they just won't work with the lift (I didn't expect to get this much height out of the AAL's/shackles). So, as a shameless plug, I've got the Toyota shocks listed in classifieds: https://forum.ih8mud.com/sale-parts/223375-fj60-shocks-new-free-shipping.html . If anyone is needing a set!

On to the photos:

 

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Hey guys, remember me? Well, I'm still alive! I've been extremely busy (2 week trip to Japan & busy time at work) but I'm back and working on the cruiser again. Thought I'd share a few photos; I've been attacking the wheel well and tailgate area rust this morning:

Left seat bracket removed:

Left seat bracket:

Right seat bracket removed:

Right seat bracket:

Left inner wheel well; brace removed:

Left inner brace:

Right inner wheel well; brace removed:

Right inner brace:

Luckily, my donor 1/4 has a clean wheel well:

Clean inside, with seat bracket removed:

 

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Continued from above:

Tailgate weatherstrip seam rust; I decided to remove the entire lower seam:

Good thing too, because the entire underside is rusty:

Pic of the seam:

Back side of seam:

Now that the seam is off, I can address the rust:

Pic with section removed:

Right side (worst side):

Cutting out the rust:

Should be an easy patch to make:

Left side rust cut out:

Left inner fender rust cut out:

Picture of the cut out area:

From another angle:

I also installed my new shocks and painted/baked/installed the exhaust manifolds; no pics of that though.

I will hopefully make and install my patches this weekend.

Happy 4th of July!

 

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Started making patches today. Couple quick photos; will hopefully start welding in this evening.

Cutting patch out of the donor 1/4:

Patch out; some rust, but should be manageable (now soaking in muriatic acid to clean remnants):

Bending patch for hatch opening:

Patch cut and test fitted; looking good so far:

Patch compared to old rusted section:

Patch for LH side:

Pic of all patches:

Time to weld em' in!~

 

[mot]

You're a little patchin' fool!!!

We'll just call you "Patch" from now on.

Thanks for letting us see the insight of the very resto job you've been doing.

As i has been said, it is truly inspiring, even for a - man like myself.

Can't wait to see the end product (Although the progress has been just as, if not more, exciting!)

Mot

 

[Joe_E]

Very cool. Everything looks awesome including the nice working area you have.

If you don't mind me asking what kind of paint you used on the frame?
I'm getting a So. Cal rot free frame from Cruiserparts and plan on blasting it and repaint, and am trying get ideas on some good paint.

 

[pint]

Keep up the good work. The truck is gonna be beautiful! I am looking at jumping into a 60/62 myself soon. Yours is major motivation on how good it can turnout!

 

[SKINNER]

Very cool. Everything looks awesome including the nice working area you have.

If you don't mind me asking what kind of paint you used on the frame?
I'm getting a So. Cal rot free frame from Cruiserparts and plan on blasting it and repaint, and am trying get ideas on some good paint.

Thanks man! It's a semi-gloss black implement paint (sold at farm supply stores). I sprayed 2 coats of it over 2 coats of Rust Bullet. If you want to see pics, I think they are on the first or second page. Thanks again!

 

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Here are a few pics with the first 2 patches welded in. They turned out pretty good.

I'm leaving the last patch out until I can get some Waxoyl or cavity wax to spray in the back x-member.

Here is a couple pics after smoothing the welds:

I also pulled out my replacement doors (the stockers are full of rust on the bottom seams). I stripped everything out of these, they all have varying degrees of dents/dings; but they are all 100% rust free. I started sanding them down tonight to prepare for bodywork.

 

[Cruiser Jimmy]

Moving along very nicely.

Makes me wonder what I should do, .... Put my 60 body on my 80 frame and use a 4BD1T for power.


......And take some que's from your body restro...

Nice work

 

[SKINNER]

Moving along very nicely.

Makes me wonder what I should do, .... Put my 60 body on my 80 frame and use a 4BD1T for power.


......And take some que's from your body restro...

Nice work

Thanks man! I'm having a good time so far, and that's all that really matters, right?

60 to an 80 frame swap and a diesel sounds like an awesome project!

 

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Js

Just a quick pic to show my progress. Started working on the LR quarter last night. I made a jig for locating the cut lines on the body and replacement panel. Should be off tonight.

 

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LR 1/4 is off, and surprise . . . . more rust! Couple pics:

Don't think I ever posted finished pics of the tailgate/hatch area; 5 total patches:

Drilling spot welds for LR 1/4:

C & D pillars cut; 1/4 off:

1/4 off:

Old 1/4:

Cutting rust out of inner well, floor, underbody well, etc:

From below:

Pics of the 4 panels to replicate/repair:

As she sits now:

 

[Project60]

Looking Good! I have been waiting for an update.

 

[SKINNER]

Looking Good! I have been waiting for an update.

Thanks man! Yours is progressing better than mine.

I admit, I lost a little momentum the past few weeks. I've been put on a new project at work that has me working late and traveling quite a bit. Sometimes it feels like a chore to come home and work on the cruiser; either way, it needs to be done so I'm back working on it.

 

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Alright, I admit that it isn't 100% cruiser related, but I thought I'd share. I spent Sunday cleaning up my new purchase (WF Wells A7 BandSaw); here are a few pics. Should come in handy with the cruiser, the increasing roll cage business, and upcoming sheet metal brake project.

As it looked when I drug it home:

After a lot of sanding and painting:

I've ordered new seals/hoses for the hydraulic feed and one bearing that was questionable. I am also going to build a new stand for easier maneuvering around the shop. Also thinking about adding a cooling system to it. . . we'll see how it cuts without it. All in all, a bad ass USA built saw with a 12" capacity! I'm stoked!

 

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Ok, back to the cruiser. I got 2 of the replacement panels for the left rear started. Here are a couple pics:

First patch, this is actually part of the inner wheel well. The wheel well extends past the floor seam and wraps around the inner quarter. All in all, I got good fitment. Should be ready to weld in tomorrow/Friday.

Progress on the rusty outer wheel well. I decide to only repair the damaged areas for simplicity and to maintain a good datum structure. Repairing the spot weld flange:

Building the flange that mates to the outer quarter skin:

Poor man's sheet metal brake (I need to get my real one finished):

Flange finished, dimensions are almost perfect:

Got a chance to use the shrinker/stretcher, pretty cool tool:

That's it for now, spent the rest of the night working on the bandsaw stand.

 

[Project60]

Got a chance to use the shrinker/stretcher, pretty cool tool:

Dang it! I had to slot and re-weld all my radii!

Looks good!

 

[SKINNER]

Dang it! I had to slot and re-weld all my radii!

Looks good!

LOL! Man, you really should consider picking up a shrinker/ stretcher if you're going to be doing anymore work like this. Super fast and easy; beats the crap out of welding 15 slots (and then dealing with the warpage).

 

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Update!

Progress from today.

Have all of the patches welded in for the wheel well; I'm waiting to weld in the final piece until I get the 1/4 patch sized up & ensure proper fit:

Started working on the nasty rust of the inner 1/4 & underbody area:

I didn't see an easy way to skip replicating the factory body lines, so I built a "hammerform":

Practice run on the hammer form:

I cut out a patch piece and started chipping away on the hammerform:

Test fit:

Basic concept:

Final "form" (on the left) after some hammer/dolly work and hitting it with the shrinking disc; notice how lumpy the other "form" is:

Finished piece:

After weldable primer: