CJ's FJ45 Restoration

[Cruiser Jimmy]

Yet another restoration!

Got this 45 from my buddy 'The Commander' who got it from another club member who got it from some guy in Canada many years back.
The project came with two rear beds, one tub and two firewalls.

The tub and firewall was bastardized with the wrong firewall, so I'm mating the correct years firewall/tub. Both need a lot of metal work to say the least.

The bed that is on now is a piece of work. It's got double skins on the outside just like the tub. The second bed is much better and I'll be putting it on instead of the current one.

The general look is going to be a matte tan or desert tan finish with black rims sitting on an SOA and 35's. Love that look!!



In lieu of taking the rusted piece out and replacing, it the mates in Canada added a second skin to the outside back corners of the tub. From the rocker back around to the back wall of the tub.


The drivers side of the tub has some pretty bad rust so that's going to need a lot of TLC.


Heading to a blaster so that I can make shorter work of the needed body work.

 

[Cruiser Jimmy]

Here's the drivers side. Yuck!!

 

[In2cruisers]

What year is she?

If you end up with a spare set of rear turn signals and/or tailgate hinges... I'll be glad to lighten your load.

Wow looks like...well...you have your work cut out....keep us posted on your progerss

 

[Cruiser Jimmy]

1978.

I'm sure I'll be selling off the excess parts since I have two of everything.

Going to strip down the doors and windshield assembly today. It stopped raining in Indy so I might get to the blaster today.

 

[4rnr]

Good to see you getting off your arse.

We pulled your drive train out on Tuesday. Its sitting in my friends garage.

 

[Cruiser Jimmy]

Sweet. Nice to hear.


Anyone have a front drivers side apron?

 

[4rnr]

Sweet. Nice to hear.


Anyone have a front drivers side apron?

So you are interested in it? We weren't 100% sure if you wanted to use this setup. If so, PM "Mr.Bryan" you guys can iron out the details.

Everything is there, motor, trans, t-case, ecu, harness, cruise, all accessories, charcoal canister, etc.... The exhaust is no good beyond about 12" after the head ( I know how expensive exhaust parts are for that motor!!) But it would be easy to fab off of that.

 

[Gumby]

It would be pretty sweet with a 1FZ in it. I don't think I have a lot to worry about not being the first one done. Looks like you have a ton of work, even if you do get a break from the road. I don't think I have an apron. I'll have to look.

 

[In2cruisers]

Sweet. Nice to hear.


Anyone have a front drivers side apron?

Think I have one.... let me check..will get back to ya

P.S. Well, put me down for the rear hinges and tail lights..

 

[Cruiser Jimmy]

I might have stupid questions about 40's over the course of this process where I can't find an answers via search.

In2: Currently I work on the road in marketing and have short periods at home but have off during the winter months, Nov ~ late Feb. The cab restoration is the main focus for me during this time. The bed restoration will not happen for sometime so you could be waiting for the hinges. The tail lights like exactly like a 40, is there a difference?

 

[Gumby]

My 63 tail lights are round and mount to the end of the frame crossmember. The ones that came in the truck were Jeep type. I found the round ones in a box of stuff I got from Brother Andy when he got out of cruisers.

 

[dr_claw]

Wow, that is in great shape! (At least compared to how mine started out )

 

[Cruiser Jimmy]

Got the 45 back from the blaster on Monday afternoon. The morning was drizzly so I relied on a friend with an enclosed trailer and kept covered until priming. Primed yesterday with it still raining so I got the parts acclimated to the garage with heat. Luckily the parts did not get rained on.

I could not believe the transition from old parts > blasted part > primed. After the parts were all primed you could really see what the elements have done to the metal over the years.

Since I have limited sheet metal working skills I'm relying Buckroseau's LV and 45 threads to see the tips and tricks as well as visuals on what the 45 tub should look like.

I'm going to start on some scrap pieces of sheet metal to dial in the Miller 172 that I have and practice. Then I'm start small with one little cut and weld on the firewall. Eventually moving to the bigger pieces. This will be a learning experience for me to say the least.

Any ideas, tricks or epiphanies that you'd like to share, please do.

Here are some shots so far.

 

[Cruiser Jimmy]

more pics



Notice the piece that is right above the body mounts. This was a tacked in piece of metal that was just laid over the top.

 

[tornadoalleycruiser]

Patience, carboard templates, a bunch of spotwelding drill bits from harbor Freight and a lot of tack welds.. Flapper wheel or mini belt sander work great on grinding back down.
I also recommend a homemade "cart" to put the pieces on as your working. YOu can spin the body around while welding, it moves it to a workable height and is mobile to get out of your way when your not working on it.

 

[Gumby]

Come get my rotisserie. It's still set up for a 45 tub.

Get or make a good brake. A shear is nice too.

Flap wheels. You'll go through a few. Get a good 4" grinder. Maybe two so you don't have to switch wheels all the time.

.023 wire and tips. Go slow. tack, then tack between your tacks, rinse and repeat.

 

[2fpower]

Tornado-

That looks exactly like your tub did last year. I thought it was a picture of it at first.

Anyway, good luck, and take Gumby up on the rotisserie. It will help you greatly.

I would also recommend lots of step 5 oil. (that is beer for newbies)

 

[Cruiser Jimmy]

$16.99 Welding Jacket

Thanks for the tips. I talked with a friend about the spot weld drill bits. He said that Carquest has some that he likes. I picked one up and it looks like it's going to get a workout.


The other purchase of the day was supposed to be a welding jacket of some type. I went to Menards and they only have aprons and no arm sleeves. I then stopped for a taco at the local taco stand to ponder where I could buy a jacket. Stopped at Napa and they did not have anything.
[while at Napa the ghetto welding cart came to mind that I've seen in chat from time to time]
My epiphany synapse started working and I though about going to Goodwill for the gaudiest leather jacket I could find. As luck would have it I found her.

The jacket has to meet all my criteria.
A) The jacket needed to be one size bigger than what I normally wear which is medium. Check: it's a Large.
B) If it has a zipper there should be overlap so that when I weld sparks don't hit the zipper and I have to pull a Houdini act to get out. Check
C) If is has a liner, it most come out. Check.
D) There should be neck protection on the jacket. Check.


I give you the fashionable welding jacket, for the with the discerning taste.
It's a one mod on the jacket.
wrench: if you're an 80 owner.)

 

[My71FJ40]

Now THAT is one pimpin' welding jacket! Great idea. Keep this build info coming...subscribed! Best of Luck!

 

[Cruiser Jimmy]

12/29/11: Spent 2.5 hours cutting out firewall cancer.

Sorry for the delay. The bathroom remodel I am underway with still needed to be finished up and I'm about 99% finished.

Got the tub up on horses and started to cut out the cancer around the lower bolts where the tub and firewall mate up. The seem were the rocker mates up to the firewall was continuously welded and heated up to the point where it deformed the steel. So my friend said just cut that out and reform it. Honestly this area is the only place on the firewall that is bad.

The right floorpan directly under the body mount support had pitted cancer. That is now out and I'll start to reconstruct it.

Heading to the the metal supplier today for some 'drops'.