FJ60 Dogleg replacement and other rust repair

[woytovich]

Well I've finally started trying to patch up the rust holes on my 85 FJ60. Don't expect a show quality restoration here but maybe this will be of some help to others facing similar issues.

I am taking a autobody refinishing class at the local trade school. I took the class with the intention of "refinishing" our 71 Datsun 240z but that project had gotten mixed in with work on the 60. What that means is that I have the guidance of a 40 year old school body work guy plus access to a real paint booth and painting quality air supply (as if I'll get any of this stuff to the point of actually painting anytime soon!)

Anyway, I'll post up here once in a while... I hope it is interesting to somebody.

Below you can see the passenger side rust... I don't have a picture of the driver's side before I started but it was worse that this one. I sources some cuts from rust free trucks - both the right and left side doglegs and a right side rear quarter/corner. I also have some flat pieces I cut out of a couple of otherwise rusty FJ60 doors and tailgate. These I'll use for patching places less complicated than the doglegs.

By the way, the "dogleg" is the body just behind the rear side doors on the 60... I guess they resemble a dog's leg.

 

[woytovich]

Here are some pics of the left side replacement tacked in place. I'll try to document the right side in detail when I get to it. Suffice it to say that this required a BUNCH of cutting and trimming of both the replacement piece and the truck itself.

The replacement pieces are really 2 or 3 pieces welded together - the outside and the underside and some other section that is part of an underside body support.

Note that my rockers (the part under the doors) have been cut and capped and there are sliders in that space that are welded to the frame.

 

[woytovich]

And a couple more

 

[woytovich]

While it might not look it this is WAY better then the giant swiss cheese holes that were there. I'll have more pics shortly of the uncut replacement piece going in to the right side and some more details of the left side.

Next is to add a thousand more welds to the piece, grind and then finish. Again, I'm not looking to make this perfect, I'm looking to make it free of rust holes. Trying to bring the truck back to respectable.

 

[Heckraiser]

subscribed

 

[GLTHFJ60]

Whoa, very cool Mark!

 

[Cruiserdrew]

Amazing rust.

Time for a new car.

 

[GLTHFJ60]

Amazing rust.

Time for a new car.

I swear, you guys from the west coast are jaded.

 

[woytovich]

Amazing rust.

Time for a new car.

RUST? That's not rusty... There are NO places on the truck where you can put your fist through a rust hole.

 

[alaska60]

way to go Mark!
Ive been looking at that spot on your rig for 2 years now.....
I also like the cut and capped rockers. looks great!
Rust never sleeps!

 

[Lugal]

RUST? That's not rusty... There are NO places on the truck where you can put your fist through a rust hole.

There are on mine. Mostly in the frame.

 

[woytovich]

That's the northeast for you...