And when you're all done with those floor rust issues, try to park it inside or under a cover to prevent (or slow) their return!
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A cover beats the heck out of nightly condensation running down the glass and metal. Good idea!
- Thread starter
- #204
After looking into the rust, I tackled with help from my brother-in-law the passenger wheel well. There is definitely a long road ahead, but its nice starting to see results.
I also pulled all the old headliner out. Lots of jute up there. This is a pre-requisite to plug welding the roof rack holes.
I also pulled all the old headliner out. Lots of jute up there. This is a pre-requisite to plug welding the roof rack holes.
A nicely done welding repair. And when you start in the hard-to-see areas, you'll be an expert (well, better) when you get to the more visible stuff.
Great job! What welder are you using?
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- #207
And remember, 'a grinder and paint will make you the welder you ain't'....
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- #210
Had a good solid few hours over the weekend to get to work on the flooring.
First up was using a dry-ice and rubbing alcohol concoction to get the old butyl sound deadening off the flooring. It took longer than I expected and showed me some new rust that was hidden beneath.
I am actually really glad that I took out the old butyl, since if I hadn't it would have led to more and more hidden rust. So I would say it was worth the effort. Now I've exposed the entire metal chassis of the interior and I know exactly what I am dealing with.
I've started cutting out all the old rust and will have to weld in some patches next.
Still need to plug weld the roof. Been a little slow and tedious to get the old headliner jute off. I feel like a big welding session will be in the cards some time really soon. Otherwise, I have lots of big holes for water to keep coming into the truck!
First up was using a dry-ice and rubbing alcohol concoction to get the old butyl sound deadening off the flooring. It took longer than I expected and showed me some new rust that was hidden beneath.
I am actually really glad that I took out the old butyl, since if I hadn't it would have led to more and more hidden rust. So I would say it was worth the effort. Now I've exposed the entire metal chassis of the interior and I know exactly what I am dealing with.
I've started cutting out all the old rust and will have to weld in some patches next.
Still need to plug weld the roof. Been a little slow and tedious to get the old headliner jute off. I feel like a big welding session will be in the cards some time really soon. Otherwise, I have lots of big holes for water to keep coming into the truck!
- Thread starter
- #211
And here are some pictures of my sub-par welding job.
First time mig welding.
Hope to get better with some practice.
First time mig welding.
Hope to get better with some practice.
That looks great - good work. I must have done 20 of those 'cut and replace' jobs on my 1980 FJ40. Be sure to shine a bright light on the back side to be sure you got all the pinholes shut, and eventually, apply some grease-style rustproofing to the back side to prevent future rust through.
- Thread starter
- #213
Thanks @SteveH , Its funny, we had rain last night and that was the real test for the roof plug weld. Unfortunately it didn't hold. There were little droplets on the roof this morning. I"ll have to do some follow-up welding to get the tiny holes plugged.
Question: Won't the POR15 that I will apply and the primer and whatever paint that goes on top stop any water from getting through?
I was going to use the POR15 underbody spray on all the welded spots just to keep them protected.
POR15 Undercoating
I bought some of this already to apply under the chassis.
Question: Won't the POR15 that I will apply and the primer and whatever paint that goes on top stop any water from getting through?
I was going to use the POR15 underbody spray on all the welded spots just to keep them protected.
POR15 Undercoating
I bought some of this already to apply under the chassis.
Put very briefly: paint is not structural. Don't use it to fill holes.
Have a solid foundation (downright Biblical, here) before you apply any topcoats. People have used things like JB Weld to plug a tiny pinhole at the last minute, but weldment is better. When you are all done, the KEY THING is to rustproof from behind with a non-tar type product - think grease. And then check the grease yearly for integrity.
Have a solid foundation (downright Biblical, here) before you apply any topcoats. People have used things like JB Weld to plug a tiny pinhole at the last minute, but weldment is better. When you are all done, the KEY THING is to rustproof from behind with a non-tar type product - think grease. And then check the grease yearly for integrity.
- Thread starter
- #215
And the decade comes to an end in a few hours. I feel like I've made some decent progress on the rig this year. Happy to have taken it off-roading to both Hollister Hills and down to Joshua Tree (and back). Never broke down on any of my trips.
Also tore the truck down to a minimalist rig. Took out all the carpeting, started doing rust repair (this should keep me busy for a little bit longer), rebuilt the steering gear box and rebuilt the front axle. Not too bad when I consider full-time work, had a second kid born and accomplished a ton of work on my house (front/back yard).
In addition to all of the above, was able to buy ANOTHER LC, a 99' LC. So now I am an LC snob with two old trucks.
2020 will be a blast. I've also upped my monthly budget on the truck from $300 to $400. A 33% increase in Land Cruiser money $$$.
Things I am looking to accomplish on the build in the next year (no particular order).
Still would like to get a rear locker installed also have given some thought to an FJ80 FF Rear axle. I mean a full chassis swap would be dope, but highly unlikely. With the given budget, probably will not be doing paint this year. My neighbors can just stare at my frankenstein monster and hope I get it painted some day.
Also tore the truck down to a minimalist rig. Took out all the carpeting, started doing rust repair (this should keep me busy for a little bit longer), rebuilt the steering gear box and rebuilt the front axle. Not too bad when I consider full-time work, had a second kid born and accomplished a ton of work on my house (front/back yard).
In addition to all of the above, was able to buy ANOTHER LC, a 99' LC. So now I am an LC snob with two old trucks.
2020 will be a blast. I've also upped my monthly budget on the truck from $300 to $400. A 33% increase in Land Cruiser money $$$.
Things I am looking to accomplish on the build in the next year (no particular order).
- Finish rust removal (welding, patching, POR15, primer)
- Get prepped for paint job
- Swap out old gaskets (window, door jambs, etc)
- Add sound deadener throughout interior (doors, flooring, roof)
- New carpet
- New Headliner
- Finish brown to blue/grey interior swap
- Old Man Emu lift (2-3") ?
- New Tires ( Falken AT3 maybe)
- Regear for larger tires
Still would like to get a rear locker installed also have given some thought to an FJ80 FF Rear axle. I mean a full chassis swap would be dope, but highly unlikely. With the given budget, probably will not be doing paint this year. My neighbors can just stare at my frankenstein monster and hope I get it painted some day.
- Thread starter
- #216
Last drive of the year...
- Thread starter
- #217
As its now May and the last posting on here was December of last year, I have a few updates to add to the thread.
First up, I've spent some time going through and cutting out more rust. I haven't prioritized my crappy welding skills so I have done a better job cutting out rust then repairing it. As a bonus, since its completely stripped on the interior I've been able to use it for hauling trash, picking up lumber and doing projects without worrying about damaging anything.
Instead I've been doing some mechanical fixes with parts that I purchased over the last two years but were too lazy to install.
Also, been spending time working on my 100-series, so that is where my budget and time has been going over the last five months.
First up, I've spent some time going through and cutting out more rust. I haven't prioritized my crappy welding skills so I have done a better job cutting out rust then repairing it. As a bonus, since its completely stripped on the interior I've been able to use it for hauling trash, picking up lumber and doing projects without worrying about damaging anything.
Instead I've been doing some mechanical fixes with parts that I purchased over the last two years but were too lazy to install.
Also, been spending time working on my 100-series, so that is where my budget and time has been going over the last five months.
- Thread starter
- #218
One of the jobs that I think I worked myself up over was the Galley Plug Fix. It was not as hard as it turned out to be, but I think that would be because I was super prepared having read through multiple threads here on the forum. I also had all the tools and parts beforehand, so it went fairly smoothly.
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- #219
Once I added a few drops of red threadlocker on the hex screw it was happy sailing. The biggest dreaded portions were drilling out the old plug and carefully tapping the whole. With the angle drill bit it made drilling out the plug pretty easy. The tap was just a slow and tedious process with some grease to grab the shavings.
- Thread starter
- #220
Tapping the good ole' 3FE was a little scary - but I was just careful with it.
Get some grease on that tap!
Get some grease on that tap!
