Hj61 sahara overhaul

[goldchaser]

The rear door hinges were the worst,exept for the bonnet hinges as they had maybe an inch play.Fixed them also.
The top tailgate hinges are 6mm pin(this one punches out,no grinding) and around 9.5mm outside bush id so i took them out to take the 8x10 bushes also,the door side hinge lost some material but i think its still plenty strong enough,time will tell.
The bottom hinges were 8mm pin i think but i still had to drill the body side to take the new bush,one side i drilled right through but the next one i only went in say 15mm to cover the lenght of the bush and it was a little tighter fitting,drilling right through reamed it out a little more.

Man my bonnet hinges were bad,i drilled a small pilot hole in the riveted side(see the spare one in the photos,its not drilled but you can see the rivet) then drill the old pin out with about a 6mmm drill then knock it out,both sides are slightly recessed and its hard to get a grinder to knock the head off the rivet,drilling was easier for me.After the pins out bang a 10mmm hole through them then i used a high tensile small bolt with enough shank to make the distance then weld the bolt/nut either side after tightening it.
Then i had to grind about 5mmm off either side of the nut and bolt as the hinge has a narrow gap to go back in through.There is no bushes in the bonnet hinges.

 

[goldchaser]

Bonnet hinges,not cut or welded yet.

 

[goldchaser]

We painted the interior yesterday morning.

 

[goldchaser]

It looks ok,inside the shed doesn't do the colour any justice.
I think it has pearl in it,if you look at it at different angles it changes quite alot,will be alot better out in the sun i think.

 

[goldchaser]

Oh here's the old bushes
Top two are the top tailgate,1 is steel,1 is nylon
The next two are the lower tailgate,both nylon.
Next two are door bushes,left one is the new ones i put in,right is the original.
Bottom ones are the drilled out bonnet pins.

 

[goldchaser]

Ah try again,im not 100% tonight,that time of year

 

[NQCruiser]

I'm envying that shed Goldchaser, I'm about to be kicked out of our workshop tomorrow and will be back to the carport at home!!

Colour is looking good too!!

 

[Michael Hanson]

A very nice looking job. Happy New Year. MIke

 

[goldchaser]

Replaced the bottom rear tailgate seal lip on the body,found a little rust on it and it was pushed down from the door closing on it over time,the new one is a whole lot thicker,it won't move.

Also found some surface rust inside the tailgate light/handle,so i drilled the rivets etc out on it and pulled it apart,it needs sandblasting and powdercoating,so now the new door handles will be powder coated black also.

 

[Trapper50cal]

This truck is going to be a beaut!

I still say you do an antique white top to give it the vintage look....

 

[goldchaser]

I'll pass on the white top thanks trapper

Now on to something more serious.
Fxxxing Toyota Australia
This is a list of a few bits i asked about from our tojo dealer:
Rear top tailgate seals,3 of them.
Windscreen seal
rear window seal
new door handles
in and outer door belts
maybe a couple of other bits

they rang a while back,out of that list in australia they have a passenger door handle and one weatherstrip for the tailgate,not sure which one but i can maybe get away some similar seals for the tailgate seals,the straight pieces not the one that runs around the frame,i really need that one.
I thought a few bits might be unavailable,but
They haven't even got a fxxxing windscreen seal in the country.
I reckon there would be alot more 60's still on the road in oz then the usa?
You guys seem to have no trouble getting most parts.
To say im pissed off is an understatement
So i'll be chasing a few bits in usa,who do i speak to,cruiser dan or SOR?
Ive got 3 weeks to finish this off if possible.

 

[Trapper50cal]

alright, alright....

sorry to hear that you're having troubles locating parts

CDan, Spectre will have what you need, and yes it will be pricey.

Try Cool Cruisers of Texas for some stuff

and try Kurt at Cruiser Outfitters to see what he has on that list

 

[goldchaser]

Thanks,i looked at sors sight,they have the tailgate seal i need,i sent cdan a pm or is it better to email him through american toyota.
A quick bite for lunch then down to the toyota dealer to abuse someone,i just can't beleive they haven't got a windscreen seal in australia.

 

[goldchaser]

update on parts in oz

so i was looking for
the 3 tailgate seals
vent window seals
door belts
windscreen seal
rear window seal
door handles

not one of those items are in australia
my dealer sourced a windscreen seal from another dealer in qld,only one in oz.
they tried vent window seals,not even available in japan
but we hit the jackpot,they have tailight lenses in stock

 

[Sixty's Guy]

Did you try Rare Spares? They have a bit of gear on their website.

 

[goldchaser]

Did you try Rare Spares? They have a bit of gear on their website.

I think they have the normal aftermarket bits that everyone else sells sixty,i have before bought like the rare spares door belts,or outer weatherstrip,they are rubbish.
I had a look at my 75 troopy outer weatherstrip this morning,it mounts exactly the same as the sixty's,they are just a bit longer,easy fix and toyota has them,i might even put a few small cuts in the door to mount the 75 inner weatherstrip.
A few aftermarket items are ok but im keeping this rig for a while and don't want leaking windscreen seals etc.
Ive decided some seals i'll reuse and i had a look at a few at our local wreckers i can use,i may get a couple off sor like the rear tailgate etc as once the hinges are on its a job to replace it later,i don't want to be pulling it back apart in the future if possible.
The oem windscreen seal is gonna cost me $314.00

 

[goldchaser]

I reckon im on the home stretch,i put a big day in yesterday and the day before.The body is ready for painting,we are knocking over the roof/front cowl after my mate finishes work this afternoon,i'll post some photos tonight.I keep forgetting to take the camera with me to the shed.
It looks pretty straight considering what we started with,there has been alot of repairs,i attacked the repairs then blocked all the flat panel areas with 240 wet before priming.Then after primer ive blocked/sanded it all off with 600 wet.We had to reprime a few spots again where i busted through to metal but it hasn't been too bad,still have a couple of panels to finish(final rub on tailgates/bonnet).
Looking forward to seeing the paint on it then start the reassemble.
Ive easily got 200hrs in prep on that body so far,but im no expert,just some good advice,so ive been taking my time,i reckon my mate would do it in half that.

 

[goldchaser]

We got a bit of colour on today

 

[goldchaser]

another

 

[Trapper50cal]

Looks amazing! nice complex color (angles/variations)

Is that all your gun work? Pre-wet sand?....NICE

(on a side-note...soooo jealous of the bubble top)