corrosion inner/outer fender bj60

[haryv]

I was told by my body shop that the corrosion that is eating at the inner fender bottom lip is spot welded to a skirt that is a part of the floor or, spot welded to the floor? Can some one confirm that the inner fender that also houses the tire, is spot welded to the sheet metal skirt that is part of the floor, or spot welded?

I think the skirt can be repaired by putting on a patch. I felt the integredy of it from the backside and it felt solid.

 

[haryv]

for some reason, pics did not upload

Okay, as you can see, inner fender/skirt has big hole in it. Was thinking of finding a used inner/outer fender for the rears then cut these out, and weld in the used ones.

 

[haryv]

made a 3d illustration of the parts

Anyone here who has worked on fj60 correct me if the fenders in the illustration are incorrect or correct as far as what they would look like taken apart??.

Thanks

 

[disassociative]

I just finished welding patches into both of my rear wheel wells. My passenger side had rust in the same places yours does, though I might say mine were a bit worse. The rust on my FJ62 went all the way through the floor at the front inside corner of the wheel well (your first picture).

Your concept drawings look correct with the exception of the "skirt". I cannot speak for the BJxx series, but on the FJ62 the inner wall of the wheel well extends down below the floor behind it and is the part you see rusted out. There is a "skirt" behind it that seems to trap moisture and causes the rust problem, but I don't believe that it extends all the way around the wheel well like you show.

As far as spot welds, it could be that mine rusted out, but all I found connecting the floor pannel to the skirt/wheel well was a thick bead of silicone (or some plastic substance) where the metal was folded together. I will take some pictures of my repair job and post it tomorrow.

 

[disassociative]

Have a look at the images below, one is a shot of the patch job I did from inside the wheel well at the same location yours is showing rust. The other image is a shot from inside the cab of the same location (pardon the sloppiness of the welds, I haven't ground them down yet). I took the picture before I sanded off the paint so it is easier to see the patch clearly.

I have been doing a lot of body work over the past 6 months and I used parts from another FJ62 that I found at a junk yard to do some of the larger body repairs. I just happened to have some leftover wheel well sections from that truck that have been cut to show cross-sections of the area in question. I discovered that there wasn't any substantial steel support at the joint where the wheel well meets the floor when I tried to cut the corner sections I needed (image 2) for the inside repair job.

You can see that there are several layers of metal, but no real substantial reinforcement in the form of the "skirt" you have in your mock-up. This is why you see my additions of the "L" sections of metal joining the floor panel to the wheel well on the inside. I plan to seal the cracks off with a couple layers of bondo before painting.

Hope this helps