I want to come work with you in the garage for a week. Lol. Amazing job.
Build HJ45 Cab On HZJ80 Chassis
- Thread starter RocketIron45
- Start date
This site may earn a commission from merchant affiliate
links, including eBay, Amazon, Skimlinks, and others.
- Thread starter
- #102
Cheers ARCTICMUTT, I gotta say that building this cruiser is a lot of fun especially when I can make heaps of noise and crank the tunes as I go! Anyway, today I formed the two rear cab flange channels to support the sides of the lower cab. These were a bit of a pain to weld in due to the cross brace still being in position and everything that isn't on a rotisserie is challenging! I took photos of the passenger side, the driver's is practically identical.
I am very happy with how these turned out even with the brace in position. After I welded the pieces in I ground them down with the 5" then used a 90 degree die grinder with a 2" sanding wheel to blend the weld in to the odd shape. I don't want to use any filler on the inside of the cab so I spent extra time sanding the welds down nice. Then I welded the outer cab flange to the large panel I rolled and just tacked in. I welded this with the MIG using .6mm solid wire. This weld needed to be done before I cut the cab brace out as I can't have it moving once the cab is apart for blasting/painting. Here are some photos of the cab without the brace and a bit of a cleaner floor.
The next step will be to form up the boxed sections for the floor to the long radius panels. Will post of photos of them as I make them, as always, stay tuned......
I am very happy with how these turned out even with the brace in position. After I welded the pieces in I ground them down with the 5" then used a 90 degree die grinder with a 2" sanding wheel to blend the weld in to the odd shape. I don't want to use any filler on the inside of the cab so I spent extra time sanding the welds down nice. Then I welded the outer cab flange to the large panel I rolled and just tacked in. I welded this with the MIG using .6mm solid wire. This weld needed to be done before I cut the cab brace out as I can't have it moving once the cab is apart for blasting/painting. Here are some photos of the cab without the brace and a bit of a cleaner floor.
The next step will be to form up the boxed sections for the floor to the long radius panels. Will post of photos of them as I make them, as always, stay tuned......
- Thread starter
- #103
Been a little while since my last post, unfortunately not much has happened since then, until today! I finally formed up the two rear cab skin to floor panels out of some more 1.2mm zinc. If the original ones were in good shape I would have just extended them but, as the norm for this build, I might aswell fabricate them from scratch
I had contemplated stamping a rectangle or something into the centre of them to strengthen them, but after forming them up they didn't really need anything. As always, I took photos of what they started out as.
With the panel formed, I used a pneumatic hole punch and cut some 4mm holes in the panel's flanges to which I will plug weld the panels to the cab then grind flat later. I have used this technique a few times on this build and I personally prefer it to using a spot welder as the spot welder leaves a divot in the panel where as the mig doesn't if you put enough weld on.
Here it is in position, after a bit of notching and stuffing around, the fit was pretty good both sides. Before welding the panels in I ran a line of sikaflex sealant on the floor to outer panel to help seal it from the inside. I am quite confident that rust won't be an issue for at least 10 years with all the zinc panel's being further coated with cold galv before being sealed up for good.
With the panels welded in, I just have to sand the welds flat to give the look of factory fit(I hope). I now turn my attention to mounting the seats before I get the upper cab extended panels sealed. I want to ensure that the seat belt's top hanger is still usable 75mm back as putting another nut and brace in can be done before sealing the panel, not after. Should have another update in another day or two. Stay tuned....
I had contemplated stamping a rectangle or something into the centre of them to strengthen them, but after forming them up they didn't really need anything. As always, I took photos of what they started out as.With the panel formed, I used a pneumatic hole punch and cut some 4mm holes in the panel's flanges to which I will plug weld the panels to the cab then grind flat later. I have used this technique a few times on this build and I personally prefer it to using a spot welder as the spot welder leaves a divot in the panel where as the mig doesn't if you put enough weld on.
Here it is in position, after a bit of notching and stuffing around, the fit was pretty good both sides. Before welding the panels in I ran a line of sikaflex sealant on the floor to outer panel to help seal it from the inside. I am quite confident that rust won't be an issue for at least 10 years with all the zinc panel's being further coated with cold galv before being sealed up for good.
With the panels welded in, I just have to sand the welds flat to give the look of factory fit(I hope). I now turn my attention to mounting the seats before I get the upper cab extended panels sealed. I want to ensure that the seat belt's top hanger is still usable 75mm back as putting another nut and brace in can be done before sealing the panel, not after. Should have another update in another day or two. Stay tuned....
- Thread starter
- #104
Update. Today I set up the two front seats in the cab and folded up some mounting pressings. After a bit of stuffing around with the seat heights and locations, I finally got some templates made. I started forming up the channels in sections as the heights of the seat mounts differ. These seats are genuine HZJ80 front buckets which are designed to fit a moulded floor, so there will be a little bit of work involved in making the mounts look remotely factory neat. I started with folding sections to suit the height and shape of the mount and then tacking them together with a section that will hold them in line with each other.
Between the seats will mount a centre console that I will fab later, most likely out of aluminium wrapped in carpet/vinyl but will decide on after finishing the cab. I checked the seat belt and all is good as far as location of everything goes.
This is about as far as I got today, will post more as it develops, stay tuned.......
Between the seats will mount a centre console that I will fab later, most likely out of aluminium wrapped in carpet/vinyl but will decide on after finishing the cab. I checked the seat belt and all is good as far as location of everything goes.
This is about as far as I got today, will post more as it develops, stay tuned.......
I know I sound like a broken record but your attention to detail is inspiring to say the least...
- Thread starter
- #107
Another weekend, another little step closer to finishing.... I fabricated and primed the rear seat mounting channel. Firstly, I began with 2mm zinc, folded up small sections to suit the uneven shape of the 80series seat mounts. With those bolted to the seats themselves, I basically filled in the area between the mounts and formed up the pieces to make an almost stamped-look hat channel. The front one will be made like this to give the impression that these are original seat mounting sections I hope....
These sections have welds on the inside so they will never loose strength from being ground flat and blended as they are. The section has a slight bow in it which I will fix with the oxy-torch shortly. The mountings will all have M12X1.25 metric fine nuts welded with compensation plates so they will never ever move.
I intend to move on to the front section as soon as I have worked out its mounting hole centres and have time of course. As Always, stay tuned for more....
These sections have welds on the inside so they will never loose strength from being ground flat and blended as they are. The section has a slight bow in it which I will fix with the oxy-torch shortly. The mountings will all have M12X1.25 metric fine nuts welded with compensation plates so they will never ever move.
I intend to move on to the front section as soon as I have worked out its mounting hole centres and have time of course. As Always, stay tuned for more....
- Thread starter
- #108
Its been a while since my last post, spare time has been difficult to come by lately but today I finally had a chance to make some progress with the build. Firstly, I centred and cleco'd the seat mounting pieces in and put the seats in back in storage. I also went to work finishing the rear window panel's stretch. Here are some photos....
I will weld the panels in next weekend hopefully and with a bit of luck it will look factory. I was going to make a stamp and put a small rectangle in the panel but oh well, I will be happy with this being flat anyway. I also added some supporting pieces running across the extension join to assist in making it solid. Will add photos next week of the panel welded and sanded smooth. As always, stay tuned for more.....
I will weld the panels in next weekend hopefully and with a bit of luck it will look factory. I was going to make a stamp and put a small rectangle in the panel but oh well, I will be happy with this being flat anyway. I also added some supporting pieces running across the extension join to assist in making it solid. Will add photos next week of the panel welded and sanded smooth. As always, stay tuned for more.....
Hi again, been awhile since I checked in. Really like this, brings up the question, the way you are building the seat mounts. I know that your reg's down there are pretty strict, are these being built for future inspection, or are you just f'n crazy about doing a better job than Toyota?! Kidding aside, the steering assembly is from the 80, right? As usual, I learn from others, and I'm learning lots here! Keep it coming, can't get enough ideas, either.
- Thread starter
- #110
G'day Cruiserpilot, yes, these are being built for future inspection and I try to make every effort to fabricate everything to a standard I am proud of basically. The whole intention of this build is to make this cruiser one that I can show off, even down to the smallest detail where possible. And yes, the steering column and linkages are all stock 80 series. The column might need to be lifted about 25mm more for proper use of the tilt function but either than that its all pretty well good to use. Anyway, will update when more progress is made........
Any updates?
- Thread starter
- #112
Update Time! The last few weeks have been pretty hectic for me at work, which means the build has stalled a little bit. However, I had some time up my sleeve today and got stuck into the upper cab interior fill-in panels. I had them tacked in and just begging to be welded and finished off, so I grabbed the MIG and initially put a few more tacks across the joins to reduce panel distortion. I had a tack about every 20mm along the entire length of the join, with it tacked I placed stitches and staggered them, working both panels so to minimise distortion. With both panels welded and cleaned, I gave them a coat of primer and while not completely welded (cant fully weld a lot of sections until the cab has been pulled apart) they do look pretty good I reckon. I did have to slide-hammer a couple of places along the weld as the panel had deformed but either than that, I thought it was pretty easy.
With the panels sanded and blended smooth, I turned my attention to the dash/steering column as I found out when installing the seats, the wheel needed to be lifted by about 25-30mm in order to gain full function of the tilt. I also wasn't really happy with my previous work on the fitment of the column and wanted to fabricate the firewall-dust seal holder better than my previous effort. Firstly, I made a straight pressing for the dash panel out of 1.2mm zinc and set to work forming up the rough shape of the panel. I decided to remove the 3mm bracing I tacked in to support the column in favour of a formed panel spreading the load across the entire width of the cab.
For the instrument panel, I was thinking about forming something to sit the speedo/gauges off the dash itself, rather than having them sit flat with the panel like original cluster. I will cross that bridge when I get to it basically. Anyway, hopefully get more done tomorrow, as always, stay tuned....
With the panels sanded and blended smooth, I turned my attention to the dash/steering column as I found out when installing the seats, the wheel needed to be lifted by about 25-30mm in order to gain full function of the tilt. I also wasn't really happy with my previous work on the fitment of the column and wanted to fabricate the firewall-dust seal holder better than my previous effort. Firstly, I made a straight pressing for the dash panel out of 1.2mm zinc and set to work forming up the rough shape of the panel. I decided to remove the 3mm bracing I tacked in to support the column in favour of a formed panel spreading the load across the entire width of the cab.
For the instrument panel, I was thinking about forming something to sit the speedo/gauges off the dash itself, rather than having them sit flat with the panel like original cluster. I will cross that bridge when I get to it basically. Anyway, hopefully get more done tomorrow, as always, stay tuned....
- Thread starter
- #113
So, been a little while since my last post, things have been hectic, have achieved something today though. I formed up the firewall/steering column seal panel out of some 1mm zincanneal, as always. The whole idea of this is to have a radius panel formed up to help hold the steering shaft seal and to have enough room to remove the bolt holding the shaft to rag joint whilst in position. I began with a piece that I hand formed in a set of pinch rollers, then made some cuts in order to shape the radius corners to allow it to be all blended nicely.
After getting it formed I TIG welded all the seams up and then proceeded to blend the welds in to create a nice almost stamped-like section.
Because I love a bit of a challenge, after forming this section, I discovered that one of the corners of the panel was fouling on the booster.
, Oh well, I did this last modification without taking too many photos unfortunately, sort caught in the moment and all. This is what I came up with, all tacked to the firewall.
I am happy with how it turned out so far, I will leave it just tacked until its on the rotisserie or I have gotten rid of the motor then I will most likely TIG it in then blend it flush like it was never welded. A keen eye will note that the stiffener that runs from the cab mount, to past the booster, then to the top has been removed. I had thought about retaining it but for the hassle it would have caused sitting there, it had to go. I will form up a new one later which will run a very similar route to the new cab mount then to the top. Should update again tomorrow if I have the chance to work on the beast! Stay Tuned!
After getting it formed I TIG welded all the seams up and then proceeded to blend the welds in to create a nice almost stamped-like section.
Because I love a bit of a challenge, after forming this section, I discovered that one of the corners of the panel was fouling on the booster.
, Oh well, I did this last modification without taking too many photos unfortunately, sort caught in the moment and all. This is what I came up with, all tacked to the firewall.I am happy with how it turned out so far, I will leave it just tacked until its on the rotisserie or I have gotten rid of the motor then I will most likely TIG it in then blend it flush like it was never welded. A keen eye will note that the stiffener that runs from the cab mount, to past the booster, then to the top has been removed. I had thought about retaining it but for the hassle it would have caused sitting there, it had to go. I will form up a new one later which will run a very similar route to the new cab mount then to the top. Should update again tomorrow if I have the chance to work on the beast! Stay Tuned!
- Joined
- Dec 8, 2006
- Threads
- 158
- Messages
- 2,974
- Location
- Greenfield, MA
- Website
- thecarpentryway.blogspot.com
Great fabrication!
- Joined
- Aug 18, 2013
- Threads
- 1
- Messages
- 7
Hi,
You may like to look at my post. I am doing something similar.
Are you going to use the 80 series engine?
My post is the 11inch wider HJ47.
You may like to look at my post. I am doing something similar.
Are you going to use the 80 series engine?
My post is the 11inch wider HJ47.
- Thread starter
- #116
Hey Sand Storm, your conversion is looking like fun, at the moment I will most likely use a Holden 5litre injected v8, if I had the factory 1HDT and gearbox bolted in place when I bought it, it would have stayed. Cheers Henry. I do try!
- Thread starter
- #117
After getting the firewall sorted, I turned my attention to assembling the front end and mudguards. As I had originally intended to use these guards on the 45 chassis with 12.5" tyres, they are about 80mm not wide enough at the front. Oh well, just a bit more modifying to do and these should be sorted. I intend to make the front mount point for the apron out of stainless and use a rubber mount in there somewhere, but for now this bracket will be good enough to hold it together.
You will also note the piece of folded galv which is clamped to the front of the guards, that is actually holding them square at the front while I figure out how to make the mounts for them.
I guess I will have the inner guard and bracing rubber mounted to the top of the spring tower. I might even fab another bracket to bolt to the chassis where the bottom corner of the apron bolts to the inner guard.
Hopefully with my shiny stainless indicator boxes and a nice looking bull bar, the extra wide guards shouldn't look too out of place. If things go to plan, next weekend I should have at least a mock up of the mudguard brace and maybe even widen the guards at the front! As always, stay tuned!!
You will also note the piece of folded galv which is clamped to the front of the guards, that is actually holding them square at the front while I figure out how to make the mounts for them.
I guess I will have the inner guard and bracing rubber mounted to the top of the spring tower. I might even fab another bracket to bolt to the chassis where the bottom corner of the apron bolts to the inner guard.
Hopefully with my shiny stainless indicator boxes and a nice looking bull bar, the extra wide guards shouldn't look too out of place. If things go to plan, next weekend I should have at least a mock up of the mudguard brace and maybe even widen the guards at the front! As always, stay tuned!!
Looking good...as usual!!! Keep the updates coming. 
- Thread starter
- #119
Another update, weekend just gone I attacked the front guards, making them wider at the front to pickup the apron. I didn't take any photos of them when I welded the pieces into them as I was on a roll and didn't want to stop for nothing! Instead of widening the entire guard, I opted for tapering the guard from centre to front. As I handmade the mounting sections to suit these 2" wider guards to the 45 chassis, I will be cutting them up to mount the guards to the 80's chassis. I will most likely have the mounting points for the guards on the top of the spring tower. Here's a couple of photos of the guards bolted to the cab and apron...
I am currently thinking about adding a pair of body mounts at the front of the chassis to help mount the inner guards/apron which might help strengthen the whole front end. Anyways, can't do too much this weekend coming, but the one after I will hopefully get stuck in! Stay tuned........
I am currently thinking about adding a pair of body mounts at the front of the chassis to help mount the inner guards/apron which might help strengthen the whole front end. Anyways, can't do too much this weekend coming, but the one after I will hopefully get stuck in! Stay tuned........
