Building out the 78' Pig (1 Viewer)

[Showerhammer]

I have had a few people ask on Facebook how I removed the rear window with the tracks misaligned with the window.

As you can see there was quite a bit of an angle difference between the track and the window. This is the driver side, passenger side was not as bad but still a slight angle.

After much debate I decided that the only thing to do was to cut the tracks off the door. Luckily they were only secured at the bottom. I cut bot sides.
Driver side

Passenger Side

As you can see from the first picture the foam had all but deteriorated. The passenger side had similar foam but also a corrugated metal inner sleeve. This was bent and preventing me from sliding the window down further. The only way was to remove the inner sleeve. Needle nose plyers for the win, Just had to man-handle the metal until it finally was down far enough for me to take the window all the way down.

 

[Showerhammer]

I decided to start getting rid of the built in trash cans and build out the floors in Old Man Tan. I didn't spring for the weld this time and decided to use rivots instead.

Right below the rear seat. Not done yet, drill bit broke and didn't have another one the right size.

 

[PabloCruise]

Alright my fellow enthusiasts of everything old and beautiful.
I am going to take on the task of refabricating the rearcorner panel. I plan on doing it all via hammer and hand cutting.
I have spent the last six months watching videos on people doing similar so I figure why not give it a shot, I have to start somewhere and after developing software all day I prefer to use my hands over machinery.

I have never taken on a project like these before I just wanted something to get me into the mountains. The two FJ-55's have become my zone to decompress from my day to day. Love the community as well. I am hoping to get Old Man Tan off-road worthy this summer to hit some easier test trails this fall in Northern Utah. Just need to get the e-brake installed and adjust the carburetor.

Back to the rear corner panel. The first of which will be many questions is, what gauge steel should I use?

Do it!

As @bobm says - it's only metal!