Guidance on rust repair

[mccubbing]

My first posting, I have a 78 Toyota BJ40 Canadian model if that makes any difference, 96 thousand original kilometers. My older brother bought it new, drove for 2 years and sold to an uncle who never drove it off the farm. Has sat for the last 30 years. Now I am starting a restoration. Mechanically its in excellent shape and all original down to the floor mats, even the tires are original I believe. I have most of the body parts I feel I need from Cool Cruisers and am getting into it. My question on replacing the rear sill, I'm sure its mentioned here but could someone point me to the postings. I am not planning on lifting the body off the frame, just replace the frame mounts, and see that the rear sill has 4 mount points to the frame. When replacing it is it best to mount the new one onto the frame and then weld onto the body. What are the recommended steps? Keeping the alignment, etc.

 

[iam_turner]

Sick 40! That looks like it's been kept very well...
check this one out Bumps on my 78’s rear tub/fenders? - https://forum.ih8mud.com/threads/bumps-on-my-78s-rear-tub-fenders.235482/, believe on one of the sites CCOT, or SOR, there were instructions on bracing - good luck, make a thread, show us the process, do the work and show her off! Welcome to mud.

 

[brooklyn]

I used real steel for the rear sill and quarter panels. Qualify was good, but needed a little adjustments to fit properly. I had a body shop do the work, so I can’t provide much on best approach.

Greatly pin stripes!

Good luck bringing that back to life!

 

[fjwagon]

Those factory stripes are pretty cool.

 

[rkymtnflyfisher]

@Awl_TEQ is in your part of the world, you should check out his build thread.



Give me a few.

 

[rkymtnflyfisher]

81 BJ42 - I have to bring it home and pass inspection

A few of you may recognize this thread ---> https://forum.ih8mud.com/40-55-series-tech/404364-radd-cruisers-bj42-new-life.html Well I have in fact purchased this unit though not from Rob directly. There was another awesome cruiserhead from Calgary who bought it and after six months decided he...

forum.ih8mud.com

 

[rkymtnflyfisher]

Call Dan. See if the sills are available.

I used one in my 40, a solid work of art.

Awl_TEQ Metal Parts etc.

I got a FJ40 rear sill from Dan. Great communication and parts!

forum.ih8mud.com

 

[rkymtnflyfisher]

It is a pretty straightforward replacement.

Don't weld it to the frame.

Brace the rear opening with some angle or something, cut out the cancer, fit the new sill in place. Tack it in and move.

Make sure your body mount bolt holes are close enough to count, then send er' home.

 

[Grayscale]

There is a pad that supports the back of the tub that will likely need replacing? Mine look like wasted canvass when you look from the fender well.

I've been told that you can use a jack to tilt the tub up at the back, loosen up the mounts at the front of the main rear floor pan, and get in there. It will keep steel from rubbing on steel. The ones in front of those compression pads, they were not rusted so much as damaged from the lifting of the rear tub which had cracked the tub there.