NeverGiveUpYota
Dare me.
That patch looks awesome! I might hire you. 
Builds Build thread - Japhy the Canadian FJ62
- Thread starter diesellibrarian
- Start date
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diesellibrarian
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- #42
Lol I'm flattered, but I don't think I'll have any interest in doing this again haha.That patch looks awesome! I might hire you.
NeverGiveUpYota
Dare me.
Bend me some of the same metal sections! Or I suppose I can make a pattern too...
diesellibrarian
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- #44
It took me about a day to make the form and to rough out the patch. Just used a jigsaw and my cheapo belt sander to smooth the plywood and chamfer the edges. After that, it's just a ton of hammering, basically.
diesellibrarian
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- #45
Work has begun on getting the driver's side rear inner fender up to snuff. I'm going to have to rebuild the entire inner lip (or rather, the outer lip of the inner fender), and I haven't quite figured out my strategy for that yet, so I'm starting with the lower sections of the inner fender.
As you can see, it's a real mess:
First order of business is to remove the mud flap hanger by drilling out the spot welds. There is more nastiness hiding behind it, which comes as no surprise:
Using these sections to create templates for the replacement panels:
Mudflap mount recreated:
Rust sucks!
As you can see, it's a real mess:
First order of business is to remove the mud flap hanger by drilling out the spot welds. There is more nastiness hiding behind it, which comes as no surprise:
Using these sections to create templates for the replacement panels:
Mudflap mount recreated:
Rust sucks!
diesellibrarian
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- Thread starter
- #46
After work today I got the lower fender piece shaped. Didn't have much to go on, but I think it'll do the trick.
First test fit. Still have some cleanup work to do before I can weld this in.
First test fit. Still have some cleanup work to do before I can weld this in.
NeverGiveUpYota
Dare me.
Looks great! Thank you so much for tackling this now. It’s always nice to see how another goes at it. Rust does suck but I think salt sucks more. I was pointing out the liquid salt lines on the highway yesterday to my son while we drove. Even at 7.5 he knew enough to say ‘I wish they would just use the other kind (rock salt).’ Me too buddy.
Wed afternoon to Thurs afternoon here in my area we’re being forecasted 12-18”. Gah. It’ll be the first real dumping of the season. I’ll be up every few hours from midnight on clearing my propane furnance exhaust pipe as they are saying 1-2’ per hour. Yea who!
Wed afternoon to Thurs afternoon here in my area we’re being forecasted 12-18”. Gah. It’ll be the first real dumping of the season. I’ll be up every few hours from midnight on clearing my propane furnance exhaust pipe as they are saying 1-2’ per hour. Yea who!
diesellibrarian
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- Thread starter
- #48
All right, some major steps forward in getting this nasty inner fender taken care of:
First I had to rebuild part of the vertical support for the inner fender.
Patch tacked into place:
And then welded. I'm not doing this the way Mr. Toyota originally designed it, but then again, look how that turned out, am I right??
And, finally, with the mudflap mount attached. I can't be bothered with plug welds on this job. I'll just knock these down a bit, and everything will get a few coats of POR-15 and some rubberized coating of some sort.
Next I'll move to the front part of the lower fender, which isn't quite as rotten.
First I had to rebuild part of the vertical support for the inner fender.
Patch tacked into place:
And then welded. I'm not doing this the way Mr. Toyota originally designed it, but then again, look how that turned out, am I right??
And, finally, with the mudflap mount attached. I can't be bothered with plug welds on this job. I'll just knock these down a bit, and everything will get a few coats of POR-15 and some rubberized coating of some sort.
Next I'll move to the front part of the lower fender, which isn't quite as rotten.
diesellibrarian
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- #49
Allrighty, got the rear lower fender all done and coated in a couple of layers of POR-15. This will all be undercoated once the other crap is addressed.
And speaking of other crap, the front lower fender isn't as bad as the rear, but still pretty nasty.
Drilled out some spot welds and cut out the offending piece. This gave me a great view of the previous owner's rocker "repair."
Again made a little plywood form to shape this patch panel:
Also cut open wheel arch to make it easier to repair the inner fender lip, and to allow me to better test fit the panel I made. No going back now!
Tomorrow I'll hopefully have this all sewn up, and then I'll move on to the passenger side, which might be in even worse shape. But hopefully the skills I've gained with these repairs will make things go smoother and faster. Thanks for following along!
And speaking of other crap, the front lower fender isn't as bad as the rear, but still pretty nasty.
Drilled out some spot welds and cut out the offending piece. This gave me a great view of the previous owner's rocker "repair."
Again made a little plywood form to shape this patch panel:
Also cut open wheel arch to make it easier to repair the inner fender lip, and to allow me to better test fit the panel I made. No going back now!
Tomorrow I'll hopefully have this all sewn up, and then I'll move on to the passenger side, which might be in even worse shape. But hopefully the skills I've gained with these repairs will make things go smoother and faster. Thanks for following along!
NeverGiveUpYota
Dare me.
Awesome! 
diesellibrarian
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- Thread starter
- #51
Wrapped up the inner fender work today. Here are some pics.
First, got the lower front piece welded in:
Then I started work on fender lip. Hammered a piece of sheet metal until it approximated the compound curve of the fender:
Tacked in place, ready to be "cut and butt" into the fender. As rusty as the piece I'm replacing is, it still serves as a useful guide for the patch, which is why I only cut it out after facing the outer lip.
And fully welded in:
First, got the lower front piece welded in:
Then I started work on fender lip. Hammered a piece of sheet metal until it approximated the compound curve of the fender:
Tacked in place, ready to be "cut and butt" into the fender. As rusty as the piece I'm replacing is, it still serves as a useful guide for the patch, which is why I only cut it out after facing the outer lip.
And fully welded in:
diesellibrarian
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- #52
With the patch in place, I could finally add the lip that bonds to the outer skin of the quarter panel. First step was to roughly cut a piece of sheet metal to match the profile of the inner fender:
Once that was tacked in place, I ground it down to the meet the inner fender perfectly, and finished welding it up. Then I cut out the shape:
Again, a coat of POR-15 on the inner fender, and I should be ready to weld in the quarter panel patch that I made a couple of weeks ago.
I'm also planning out my strategy for the rusty dogleg. Back at it tomorrow!
Once that was tacked in place, I ground it down to the meet the inner fender perfectly, and finished welding it up. Then I cut out the shape:
Again, a coat of POR-15 on the inner fender, and I should be ready to weld in the quarter panel patch that I made a couple of weeks ago.
I'm also planning out my strategy for the rusty dogleg. Back at it tomorrow!
diesellibrarian
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- #53
Snow arrives tomorrow, so I was hustling today to get my 4wd back to driveable condition. Didn't get as far as I'd hoped, but anyway here's some pics.
Here I'm fitting the wheel arch patch that I'd made a few weeks ago. I debated gluing the panel in, but instead decided to use adhesive on the fender lip only. I used some sheet metal screws to clamp everything together while I carried on with the welding:
Here it's mostly welded in place. Had to use some, uh, unorthodox techniques to get everything to line up, but the goal here isn't to build a show car. It just has to keep water and dirt out, and look passable from 20 feet.
Anyway, after a coat or two of primer, I'm pretty satisfied with how it turned out. It's been a ton of work, but I saved myself $800 on a set up Wolf aftermarket panels, and have definitely added to my skills. Still needs a little more filler here and there, but I'll address that when I tackle the lower quarter, which as you can see is thoroughly thrashed. But at this point, the fender is watertight for the first time in years and years.
Here I'm fitting the wheel arch patch that I'd made a few weeks ago. I debated gluing the panel in, but instead decided to use adhesive on the fender lip only. I used some sheet metal screws to clamp everything together while I carried on with the welding:
Here it's mostly welded in place. Had to use some, uh, unorthodox techniques to get everything to line up, but the goal here isn't to build a show car. It just has to keep water and dirt out, and look passable from 20 feet.
Anyway, after a coat or two of primer, I'm pretty satisfied with how it turned out. It's been a ton of work, but I saved myself $800 on a set up Wolf aftermarket panels, and have definitely added to my skills. Still needs a little more filler here and there, but I'll address that when I tackle the lower quarter, which as you can see is thoroughly thrashed. But at this point, the fender is watertight for the first time in years and years.
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looks pretty good from 3200 klm's east of you. keep at it bud.
diesellibrarian
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- #55
Got a little work done on the 62 over the holidays, but first me and the family got out of town over Christmas to do some skiing. Love these little adventures in the Land Cruiser:
But once we got home, it was all business. I am kind of sick of working on fenders, so I decided to turn my attention to a large hole in the floor of the cargo area. This meant also patching a smaller hole in the rear passenger fender. It's pretty bad, as you can see:
The first step was to make a small patch for the fender:
Here's the fender patch welded in place, and the hole in the floor opened up to allow me to clean things up before installing the new metal. I coated the inside of the body mount with POR-15, even though it's not in terrible shape. An ounce of prevention, am I right?
And finally, the floor patch tacked in place. I used panel adhesive to glue the patch to the flat surfaces of the body mount, as well as the outer lip and the part that connects to the fender patch I'd just installed. I don't have clecos so I just used sheet metal screws to clamp the patch to the body mount while the adhesive cures. The adhesive will also act as a seam sealer in this area, to hopefully prevent future rusting.
Word to the wise if you're working in this area: make sure the rubber undercoating is removed before you start welding, as it can start to burn.
Anyway, this was a challenging patch to make and install. Back to working on the fenders I guess!
But once we got home, it was all business. I am kind of sick of working on fenders, so I decided to turn my attention to a large hole in the floor of the cargo area. This meant also patching a smaller hole in the rear passenger fender. It's pretty bad, as you can see:
The first step was to make a small patch for the fender:
Here's the fender patch welded in place, and the hole in the floor opened up to allow me to clean things up before installing the new metal. I coated the inside of the body mount with POR-15, even though it's not in terrible shape. An ounce of prevention, am I right?
And finally, the floor patch tacked in place. I used panel adhesive to glue the patch to the flat surfaces of the body mount, as well as the outer lip and the part that connects to the fender patch I'd just installed. I don't have clecos so I just used sheet metal screws to clamp the patch to the body mount while the adhesive cures. The adhesive will also act as a seam sealer in this area, to hopefully prevent future rusting.
Word to the wise if you're working in this area: make sure the rubber undercoating is removed before you start welding, as it can start to burn.
Anyway, this was a challenging patch to make and install. Back to working on the fenders I guess!
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NeverGiveUpYota
Dare me.
Tackling it better than any other shade tree pro! Love seeing your pics and detailed words. Thank you for paving the way for me.
diesellibrarian
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- #57
Thanks! That means a lot, considering that before November I'd never even touched a welder or worked with sheet metal. I'm sure I'm not doing it "right" but hopefully it gives people some ideas, if they have to tackle rust in these same areas.
NeverGiveUpYota
Dare me.
Your taking to the welder well! I learned basically everything I know from @cruisermatt via text message! What welder is it?
Nice work. That area around the drain hole is double sheet isnt it? Mine needs some work, and there is swollen blisters in various places in the wheel well from rust starting between the two metal sheets.
diesellibrarian
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- #60
It's a Lincoln 140 MP. I bought it because it'll do MIG, TIG, and stick. Have only done MIG so far.
