FJ-55 interior cargo area panels

[rsbcruiser]

FJ-55 interior panels

I've looked for years for a waterproof, durable and inexpensive interior panel replacement materiel for my FJ-55.

 

[rsbcruiser]

Recycling

I was on way to the dump with a load of household junk thinking "pity to toss that anti static mat". You know, they put them under chairs to protect computers from static. Made it all the way to the check-in line at the dump before idea one and idea two finally shook hands. I feel a how to thread comin on. Like a cold.

 

[rsbcruiser]

3M makes the mat and it cuts easy.

 

[rsbcruiser]

Layout

Use butcher paper to lay out the panel shape, mounting hole locations and the vent hole.

 

[rsbcruiser]

Fuel inlet protrusion

You will have to allow for the protrusion around the fuel inlet. Or even better, reuse your old cover. It is much easier to slot your panel for the lower flange and then mounting your old cover than performing the next few steps.

 

[rsbcruiser]

Allowance for protrusion

You will have to allow for the protrusion by leaving extra material on your rough cut panels

 

[rsbcruiser]

Same stretegy for the other side.

 

[rsbcruiser]

Use a jig saw to trim rough panels, trim to fit fuel inlet side.

 

[rsbcruiser]

Drill mounting holes

Drill the mounting holes. Make your life easy and go big. I used a 5/16" hole for 6mm screws.

 

[rsbcruiser]

Trimming out the vent hole

Drill holes for the vent. Use your jigsaw to trim out.

 

[rsbcruiser]

Extruded U nuts for mounting

Pick up some of these. Extruded U nuts. I chose 6mm X 1. Used stainless 6mm X 1 button head allen screws 5/8" long and 6mm stainless fender washers. all of that shot the budget on this project.

 

[rsbcruiser]

Installing the U nuts

Remove the plastic inserts and replace with U nuts. Tip: using your needlenose pliers, reach behind, grab the nipple and leverage out away from you, pulling it through.

 

[rsbcruiser]

Install the panels

Install the finished panels. You're done. Not me, I have to go back and remake one bacause I didn't take enough care aligning the drill holes. Doh. Forget that, I'm going forward with sound dampening and tie-downs, what the heck.

 

[rsbcruiser]

Sound deadening material

Purchased this stuff from NAPA. $26 for 5 one foot square panels. Just enough to do the cargo panels.

 

[n2666s]

awsome........now I need a source for the ubolts!

Lou

 

[FineWynsFJ40]

Awesome idea!! I'll be looking this thread up when it comes time later on!

Cheers!

Brian

 

[nuclearlemon]

looks awesome. my door and cargo panels need some attention also. i'm going to try to find some sort of stiff thin board that i can cover with the extra vinyl i have left from doing my soft doors.

 

[rsbcruiser]

best alternative material

looks awesome. my door and cargo panels need some attention also. i'm going to try to find some sort of stiff thin board that i can cover with the extra vinyl i have left from doing my soft doors.

Nuclearlemon, I think that the 3M velostat product I am using in this thread is the ticket, stiff thin board. i plan on researching it some more today. Hit a thrift store and an office supply store today. See how cheap I can pick up another anti-static mat for. I will publish $ results in the thread field above, where it applies. If you find a better alternative (cheaper, better) let me know. Bet this material price to benifit ratio unbeatable.

 

[bkfj40]

if you don't have your original panels to trace or want to make it easier on yourself, I gave my information to Woody and he put it up on the site. You can take it to a printer, engineer, architect, or whoever else that can make large format plots for you and just print out and cut along the line (or get 'em cnc cut )

linky:
http://www.ih8mud.com/tech/FJ55-panels.php


bk

 

[rsbcruiser]

Very Nice, bkfj40, thanks

if you don't have your original panels to trace or want to make it easier on yourself, I gave my information to Woody and he put it up on the site. You can take it to a printer:

Oh Man! Dang, thanks alot bkfj40. I originally tried using the panels as models. Bad idea, they were just too toast. Also, the holes in the original panel don't line up with the holes in LC interior flanges due to the mounting system design. I will look at your stuff, see if I can make it work. Using the butcher paper and jigsaw method can work ok along as you are really careful. Never produce the results like the method you suggest. bet they come out sharp! Mine, you can tell they are ameteur work.