Fergytoy's 1977 FJ40 frame off resto.

[john657]

Removing the rusted panels prior to sandblasting. Burning out broken studs in the frame. Ordered up a new 4" Hell for Stout lift from CoolCruisers.

 

[Medic406]

How goes the progress? Ever need any Junction help and someone to drink a beer while you work, let me know

 

[john657]

My apologies for such a long delay in updating this thread. I finished this project several years ago and not got around to working on this thread. So, adding in some resto pics..........

 

[john657]

More rust repair................

 

[john657]

Bending up new rollbar mounts. Approached these in a different way as to alleviate the chronic wheel-well rust issues with how the originals would trap moisture/salt at these mounts. New mounts are 10gauge steel.

 

[john657]

Tub was a bit toasty. Stripped to the point of it being ready to head to the sandblasters. This was the most rusted 40 I had restored yet it was still salvageable.

 

[john657]

Frame painted inside and out. Axles stripped, painted and rebuilt.

 

[john657]

Tub is back from the sandblasters and ready for new panels.

 

[john657]

The wheel wells were rather toasty so decided on complete replacement of them. New panels via Cool Cruisers. They fit perfectly. Really good products.

 

[john657]

Decided to build a new rear sill and to make it stronger than the original OEM. 10ga square steel tubing along with 10ga steel plate cut for the radiused ends. Rust proofed inside and out.

 

[john657]

Finishing up the panel work and test fitting back onto the chassis.

 

[john657]

Once the metal work was done, POR15 went into all the seams and then a coat of Tie-coat primer. All the seams were then seam-sealed prior to a seal coat of primer.

 

[john657]

Decided to go with the original color of Sky Blue and the entire bottom of the tub was sprayed with tinted EZ-Liner for better protection.

 

[john657]

In the meantime, the engine came back from the machine shop, was painted and set back into the chassis.

 

[john657]

Some more filler and light hammer work with lots of sanding. Interior sprayed with the color tinted EZ-Liner.

 

[john657]

Interior sprayed and time for more rust repair on seat mounts.

 

[john657]

Primer/sealer time for the exterior. Buddy Rocky is getting after it.

 

[john657]

Satisfying to see the top color coat going on. Layed down nicely.

 

[john657]

Tub gets bolted back onto the chassis with new urethane mounts. New 35" BFG mudders.

 

[john657]

Rear fenders were cut out to allow for the larger tires. Also trying to get my hardware selections in better order.