Builds Back in a 40! - AussieHJCruza's HJ47 Build - now back to a frame-off (1 Viewer)

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Another fender gone
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And a stack of bolts ordered from @davework - thanks for making these available!
 
So the covid stuff has stopped us meeting up for ages now, as i can't leave the state and come back without quarantining for 14 days. So decided to make a start on the drivers door today. It needs a fair amount of attention. Will be taken probably pretty slowly.

Starting with this:
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Looking at the door, I wanted to pull the 2 skins apart and do it properly. Here's how I did that:

1. Drill out the spot welds along the bottom of the door. There are 8. Working from the inside, using a 6.5mm drill bit, drill though the first skin only. Then pry it a little and it should "pop".
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Step 2:
On the crease near the door lock, there are 2 more spot welds. Looks like Mr Toyota thinks of most things, being the area that takes a lot of force from that angry guy slamming the door. These are the only 2 in the crease joints that run around the edge of the door. Again, drill out using the 6.5mm drill bit
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Step 3:
If you own a set of the right pliers to open up the folds around the edge of the door, use them. If you don't, like me, this is what I did to separate it. Using a flat bar (I used a chisel) and a good pair of nips, start at one end and pry the fold up. Use the chisel to protect the edge of the door.
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Continue right around the door until all the folds are turned up. The skins should then separate from each other revealing more rust than you knew u had.
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If i can do it, anyone can. Total time to separate the 2 skins was 1.5 hours. Including getting more beer. Now the fun part of fixing the rust.
 
It came up nicely - now I'm gonna have to get the rest of the engine clean to match :lol:

Hey just a tip for reviving old rubber.

Use wintergreen oil. It works wonders to soften and make it nice and black again. However, be careful because to much and the part will swell up like a ballon. Also wear good chemical gloves when using it, it can be toxic and absorbs into your skin.

Cheers
 
Milestone today - roof off!
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Also got U-Bolt flips and rocker protectors coming from @lcwizard and bib and door patch panels from Real Steel.
 
And a side project, giving an R32 golf a bit of a tidy up. Not a show car finish but at least the kerb rash has gone. Someone else has bogged these wheels before so ideally they need to be blasted back to bare metal but haven't got time for that
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Care package from Partsouq today, front axle hardware and rear bearings and seals, plus shift knob etc. Gotta love Mr T's attention to detail with the threadlocker on the studs etc.
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Also got some very nice goodies from @lcwizard - rocker protectors and U-Bolt flip kits - more pics of them tomorrow
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Care package from Partsouq today, front axle hardware and rear bearings and seals, plus shift knob etc. Gotta love Mr T's attention to detail with the threadlocker on the studs etc.
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Also got some very nice goodies from @lcwizard - rocker protectors and U-Bolt flip kits - more pics of them tomorrow
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so how does packing hold up on a 7800 mile journey from AZ,USA to Australia? It's always a concern to me
 
so how does packing hold up on a 7800 mile journey from AZ,USA to Australia? It's always a concern to me
Everything looks fine! The Box is a bit battered but everything inside is perfect!
 
thanks,
It's always a worry. We get packaging destroyed in 100 mile trips. I guess it's about who does the handling.
Enjoy your project. Should be a keeper when it's done.
Thanks very much! Looking forward to getting her on the road
 
Not exactly 40 related but a care package from @NLXTACY arrived, this stuff is niiiiice
Axle posters for 60 and 80 and seal drivers for the 80 inner axle seal and some stickers
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Gotta love shiny new stuff
 
Slow progress, but progress. Degreasing and high pressure washing the chassis today, amazing how much stuff accumulated in the chassis but she's clean now

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Gonna hit it with phosphoric acid next to give the rust a hard time and make sure it's properly clean. It's a bit hot here at the moment so will have to wait till it cools off, maybe this evening as I want it to soak for a couple of hours without drying out.
 
Back part of the chassis cleaned to within an inch of its life, phosphoric acid etched and then coated in zinc phosphate, before the first coat of a nice heavy urethane. Sorry, no decent pics of pre paint, was in a get it done mood.

Also pulled the rear axle, had to cut the sway bar mounts and one u-bolt, and had the second bolt in the fixed pin (no idea what the proper name is) shear the head off, thankfully there was enough thread through the hanger to weld a nut on. Tomorrow, getting the axle degreased, blasted and coated hopefully. Then she'll go back in with new bushes, pins, shackles, springs and shocks. After that, wheel bearings, seals, wheel studs etc,and depending on the condition, turn or replace the drums and get the rear axle good to go.

Not going to rebuild the diff at the moment because it wasn't noisy when driving before and hopefully one day she'll get air lockers.

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Second coat done. About to start the top coat which is also a urethane but satin black and more UV stable than the base/sealer product.

If this thing rusts again I'll run myself over with it

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