HZJ73 rust repair and maintenance

[Blue1]

I cut out all the rust back to clean metal then spot sandblasted all the rust. I think I'll still hit it with phosphoric acid to convert any rust that may remain. Last photo is the patch panel I made. I still need to do a bit of trimming to fit it up but then I'll hit it with weld through primer and weld it up.

 

[Blue1]

So I made that patch piece out of 1 piece instead of 2 like the factory floor is. I'm hoping that wasn't a poor decision I'll regret later. My reasoning is 1 less overlapping joint to seal up from future moisture and rust. I welded this one in because it was a patch and there isn't a clean way to glue where there were previously spot welds but still butt weld the patch to the existing floor panel. Body adhesive and heat don't play well together. Starting on the lower door pillar pieces pieces today. I know this is a long shot but does anyone have any photo's of the lower pillars both in front of and behind the door ? I 've looked at the parts diagrams online and have searched for photo's. I've looked through every photo of @kelly saad HJ75 restoration ( which is absolutely phenomenal rescue work ) but I couldn't see any photos of those layers in that area as it was rebuilt. If anyone can share any links that would be much appreciated !

 

[kelly saad]

So I made that patch piece out of 1 piece instead of 2 like the factory floor is. I'm hoping that wasn't a poor decision I'll regret later. My reasoning is 1 less overlapping joint to seal up from future moisture and rust. I welded this one in because it was a patch and there isn't a clean way to glue where there were previously spot welds but still butt weld the patch to the existing floor panel. Body adhesive and heat don't play well together. Starting on the lower door pillar pieces pieces today. I know this is a long shot but does anyone have any photo's of the lower pillars both in front of and behind the door ? I 've looked at the parts diagrams online and have searched for photo's. I've looked through every photo of @kelly saad HJ75 restoration ( which is absolutely phenomenal rescue work ) but I couldn't see any photos of those layers in that area as it was rebuilt. If anyone can share any links that would be much appreciated !

I just looked through my pictures and I have a pretty good video of that area that might help. PM me and I can maybe text it to you.

 

[Blue1]

I just looked through my pictures and I have a pretty good video of that area that might help. PM me and I can maybe text it to you.

Thank you, that would be very helpful. I really appreciate it.

 

[LDRF]

I'm hoping that wasn't a poor decision I'll regret later.

Keep on moving forward. It’s looking good! It’s not going to the Pebble Beach concourse, it’s going to roam the Canadian wilds!

@kelly saad , I may reach out to for you to share it with me as well. I’ve got to get into the same areas as @Blue1 in the near future. My progress has been hampered by the <-20 Celsius weather and my unheated garage.

 

[Blue1]

Finally had a chance to dig back into the left rocker and there wasn't a lot left of the inner rocker . I didn't have much to work with so @kelly saad sent me a video he had of that area. Armed with that video and what was left of the inner rocker I was able to make a piece that fit fairly well. I was being a bit lazy and didn't try to form all the pressed squares that add structure to the inner rocker but I did use a heavier gauge steel to try to compensate for that. I know it doesn't look factory but my main goal is to just eliminate all the rust I can and make it solid again. Hopefully I don't regret cutting corners later on. There also wasn't anything left of the inner panel that sandwiches between the inner rocker and the outer rocker I purchased from @joekatana so I had to make that piece as well. Again I relied heavily on the video of that are to know what I was trying to make.

 

[Blue1]

There wasn't a lot left of the rear section of the inner rocker so I made a piece for there as well. I cut the rust out and and sand blasted the inner structure with my little spot sandblaster then coated it with rust inhibiting paint and started putting it all back together

 

[Broski]

Man you have SKILLS

 

[Rigster]

There wasn't a lot left of the rear section of the inner rocker so I made a piece for there as well. I cut the rust out and and sand blasted the inner structure with my little spot sandblaster then coated it with rust inhibiting paint and started putting it all back together

View attachment 3826388

View attachment 3826389

View attachment 3826390

View attachment 3826391

View attachment 3826392

Man, I didn't even think the store had that many pairs of vice grips!
Nice work on the repairs!

 

[kelly saad]

Looks fantastic!!!

 

[LDRF]

Nice work Blue. I’ll be getting into that area as well. I don’t think my rust is as bad as yours, but who knows. I’ll find out when I take a zip wheel and spot weld drill to the outer rockers!

 

[Blue1]

Nice work Blue. I’ll be getting into that area as well. I don’t think my rust is as bad as yours, but who knows. I’ll find out when I take a zip wheel and spot weld drill to the outer rockers!

Hopefully you don’t find the surprises I did. The deeper in I got the less metal and more rust I found.

 

[Blue1]

So no progress for the last 3 weeks, I had to drive another vehicle down to Dallas for work. On the way down I did a last minute stop at @cruiseroutfit just before they closed and grabbed some shackles and bushings. I am going to try to flip my springs to see if I can reduce the pronounced right side lean I have. The new shackles will save me from dropping the tank when I do the rears.

 

[Blue1]

work has finally calmed down and I can get back to hopefully moving forward ! Lower door pillar welded back in place. It still needs a bit of cleaning up but then I'll spray it with chassis saver then scuff it up a bit and hit it with seam sealer then an epoxy primer. I should be able to hang the door back on then start moving forward on the inner fender and rear quarter

 

[Blue1]

Going to let this cure for a few days before seam sealing. Ill get the rear quarter done then seal it all at the same time and epoxy coat after. Its at least has a coating on for now. Time to hang the door.

 

[LDRF]

Looking good Blue!!!!!

 

[Blue1]

Looking good Blue!!!!!

Feels good to have time to work on it. I need to get the body done so I can start on the fun next project on this thing.

 

[Blue1]

Door is hung again and lining up fairly well. It will have to come off again at least 1 more time so I didn’t spend a lot of time on it other than confirming the lower section of the pillar I had to cut out is reattached close enough to be able to get the door to fit properly.

 

[Blue1]

The bottom of this was totally rusted away so I am guessing a bit about the piece I made to patch in. If anyone has a picture of this area they can share that would be great. ( short wheel base and troops appear to be different )

 

[Blue1]

Had to rebuild the sheet metal piece that ties what toyota calls the " pillar sub assembly, center " to the outer panel of the rear wheel well or " wheel house " as toyota calls it. I couldn't actually find the piece on the parts diagram. After that I was able to weld in that outer panel of the rear wheel well. Just needs to be seam sealed then on to the left rear floor panel build.