Decision Time - Am I Ready For A Frame Off Restoration (3 Viewers)

[TCSTARK]

Thanks to ElHefe passing on the CCOT rear quarters I didn't have to fab up a pair of home brew patch panels.

It's coming along nicely. Welding is very cool and my auto body tools actually came out of the box today.

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[Pierps]

Question. Did you cut you quarter panels using your angle grinder? If so, any tips on making a clean cut? I haven't had much success keeping my grinder under control... I'm terrified at the prospect of using it for detail work on my cruiser.

 

[Interpol]

amazing thread.

 

[TCSTARK]

Question. Did you cut you quarter panels using your angle grinder? If so, any tips on making a clean cut? I haven't had much success keeping my grinder under control... I'm terrified at the prospect of using it for detail work on my cruiser.

I have been using a cut off tool to make the cuts on the rear quarters and the patch panel. Make sure you are using a cutoff disc that is designed for sheet metal. They are a bit more expensive but certainly worth the cost. The The other technique I have been using is guiding the cut off tool with my left hand to ensure it doesn't go wildly off course.

The biggest tip I can give you is measure, measure, measure and then cut... Once I cut the rear quarter I placed the patch panel in its place and scribed a line on it and then compaired the line to my measurements. I would rather have to grind down the panel to fit than it be too short.

 

[Pierps]

Cool. Thanks. I was wondering whether a cut off tool would be easier to control. I'll be patching in new front door bottoms like you did at some point.

 

[TCSTARK]

The rear sill was primed and installed today. The body mounts presented me a slight challenge due to the tight space I had to install them.

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[TCSTARK]

Ok, I got the passenger side patch cut and in place to weld only to realize I am out of gas. Lesson #1 - turn the gas off after use.

I guess I will need to get a refill so I can weld it up tomorrow.

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[TCSTARK]

Gas was filled up and the patch panel has been completed.

Question: do I tack weld the outer sill skin to the sill? I see the holes and logically it makes sense.

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[apeterson]

nice work!!!

 

[TCSTARK]

nice work!!!

Mr. Peterson, your thread was the inspiration that got me to pull the trigger on my 40. Thanks for the compliment. Have you started on your half door build yet?

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[apeterson]

Mr. Peterson, your thread was the inspiration that got me to pull the trigger on my 40. Thanks for the compliment. Have you started on your half door build yet?

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wow... thanks man!!

yes they are started... cut and all welding and grinding is done. just starting body work. so they are moving along. more pics to come in my thread.

 

[broth9640]

Gas was filled up and the patch panel has been completed.

Question: do I tack weld the outer sill skin to the sill? I see the holes and logically it makes sense.

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That's what I did with mine. It came out great. Keep up the Awesome work!

 

[TCSTARK]

Well that is settled the outer skin will be welded to the sill. What about the edges were the sill connects to the tub? Seam sealer or welded and ground down with a Dremmel tool?

 

[broth9640]

Well that is settled the outer skin will be welded to the sill. What about the edges were the sill connects to the tub? Seam sealer or welded and ground down with a Dremmel tool?

Your quarter panels should be flush with the rear sill outer skin. I welded them together then ground it smooth. The first pic is where I welded the outer skin to the sill and the second pic is hard to see since the tire carrier is in the way, but it's the rear outer sill skin welded to the rear quarter panel. Ground it down so its flush. It should look stock when your done.

 

[TCSTARK]

Thanks man! I totally got it straight now.

 

[TCSTARK]

Ok, I test fit the tire carrier on the new rear quarters and sill and I have an issue... It appears that the holes on the sill horns and sill are not set up for the older tire carrier. Since 75 is a transition model year I purchased the wrong sill. What should I do? Should I attempt to install the tube style carrier or weld up the holes and drill a new set for the carrier and latch?

Can someone get the measurements for the tube style holes (top, bottom and latch) so i can determine which way is the best approach?

 

[Pierps]

That sucks man! Sorry to hear that.

Assuming the top holes are the same for both versions (a big IF), and assuming you aren't a purist, I'd say swap in a non-tube style carrier.

They're all over ebay for probably 100-150 bones. Of course, worst case if you try to drill out holes for the tube carrier and you get it wrong, you can just weld up the holes and try again.

So as most things FJ40, it's a time vs. money equation!

 

[broth9640]

That's a tough call. If you can get to the back side of the sill with the welder then my vote is to drill new holes and then weld up the nut so you have a factory looking captured nut. Weld up the other holes not being used. Shouldn't take you more than an hour to do. Mount up the tire carrier to figure out where the new holes will need to be. You will be richer and feel good about solving the problem.
Cheers,
Brian

 

[TCSTARK]

I confirmed the mounting locations on my sill are for the tube style carrier. The bump stop and latch positions match exactly. I found a cheap tube style carrier on eBay and the bump stop and latch on cruiserparts.net. So it looks like the path of least resistance is to do the conversion.

The hardest part will be relocating the backing plate on the upper rear quarter.

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[broth9640]

I confirmed the mounting locations on my sill are for the tube style carrier. The bump stop and latch positions match exactly. I found a cheap tube style carrier on eBay and the bump stop and latch on cruiserparts.net. So it looks like the path of least resistance is to do the conversion.

The hardest part will be relocating the backing plate on the upper rear quarter.

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Sweet! That should be easy compared to installing the rear sill!