Meanwhile, it was time to explore what lies below the little bits of spot rust I found.
What I found was a good few millimetres of bog covering some very dodgy metal work. But hey, at least there is still metalwork! Got out the chisel and hammer and got the bog out of the way.
ps. Thanks Rooboos! I'm very happy to be welcomed onto such a knowledgeable site!
I feel your rusty pain Rooboos. I found a whole new panel full of body filler with rusty bits below it this afternoon. Looks like there will be some metal fabrication involved in my on-frame rebuild, but it's less work in the long run than patching bits here and there! Some of the body filler I am removing is 1cm thick, good grief!!
You are quite welcome. I had some rust in my rig on the kick vent passenger side. I had to cut it out and weld a new piece in and fab the vent hole. That was fun lol. I also have the corner inside the top eaten away. I have to find a good tin smith here to make me a new gutter, I have several in mind that come highly recommended by the 4x4 community here as well. Lots of work but makes a guy feel good in te end. Over all my floor pans are in great shape considering where I am. Biggest problem I have encountered is the gutter channel, and the door bottoms and the kick vent at the cowl.
I have a few FJ40 projects coming up, that are tempting me to take up MIG welding. Is this hard to do? The online videos make it look pretty reasonable. I don't need pretty welds, just strong and functional.
And I'm thinking, maybe MUCH later.. if I have rust to deal with, I can cut it out and weld? This is a dumb question, but what kind of metal do you use to repair panels? I'm assuming some kind of sheet metal? But thickness? I see terms like cold-rolled, or something like that. Anyways, sorry to hijack..
Welcome to Mud Gruntled!! At least your bezel is correct.. ************