I found an awesome deal on a great tub... obviously, there’s a catch.

[BIGTOM]

Howdy all!
After some soul searching, I decided it’d be worth my while to proceed with the 66 FJ40 project that my son and I were working on. For a short time, I thought about selling her, but talked to a guy who knows a guy who’s got a ton of parts. <— thought it was the same song we’ve all heard before - just a different verse. The guy was busy with life like all of us and he did give me directions to the FJ guy’s place. I went out there and... yeah - he had quite a bit of stuff. We checked out what he had and came upon a pretty much rust-free tub (see first photos and note the driver’s rear quarter) which looked gorgeous except for where a tree had fallen on the driver’s rear quarter. I’m not going to bore you with my rusty tub as we all know what they look like lol - but I decided this could be brought back. I’m in the process of straightening the driver’s quarter and it’s going pretty well - the obvious difference is this tub is from a 73 and has a few differences, but considering how rusty mine is and how complete and clean this one is, I don’t care. Regardless, I’m planning on driving mine and doing a brake swap etc. so originality be damned. I’ve been able to straighten everything pretty square considering the HUGE dent (where I’m pointing in one of the photos was how far down the metal was pushed) it had. I’ve maintained the body lines for the most part and I think with an eventual skim coat of filler, it should be in pretty good shape. Feel free to comment, throw me under the bus etc. I’ve got teenage daughters, so I’m pretty thick skinned right now. I’ll post more as I continue.

 

[BIGTOM]

Progress thus far...

 

[BIGTOM]

My most important tools to this point are my measuring tape and square.

 

[SteveH]

It's a labor of love, for sure. Looks like good progress. Go slowly and take your time.

 

[BIGTOM]

It's a labor of love, for sure. Looks like good progress. Go slowly and take your time.

Heck yeah! Slowly tapping at some points. I’m going to build a stand for it to sit on and be easily moved. After it’s sitting on something that resembles the frame but made of wood - I can straighten the bottom areas which are in much better shape.

 

[Living in the Past]

Have you thought about welding in the top section from another tub? That section a lot of times is not rusted like along the bottom.

 

[bikersmurf]

That looks more like a ‘74. But it’s so far gone you should just let me recycle it for you... I’ll come by and remove it for you.

 

[BIGTOM]

Have you thought about welding in the top section from another tub? That section a lot of times is not rusted like along the bottom.

I have thought about that. I got this one pretty straight, BUT it’s not laser straight like the other side, so we’ll see. The last thing I want to do is replace that thing if it doesn’t look right after I’m done welding it in place.

 

[BIGTOM]

That looks more like a ‘74. But it’s so far gone you should just let me recycle it for you... I’ll come by and remove it for you.

LOL - yeah, I think you’re right that it is a 74 tub. My 66 floor is so thin I can read a newspaper through it! I’ll post some photos of what I’m replacing for sure.

 

[Drake2]

I'm so glad you posted this because if that can be saved their may still be life left in saving mine ......I will be watching your progress and if it turns out good, I have a job for you

 

[BIGTOM]

I'm so glad you posted this because if that can be saved their may still be life left in saving mine ......I will be watching your progress and if it turns out good, I have a job for you

Once I started peeling the skin off the top where it folds over, the metal acted like it wanted to spring back into shape. After I cut out that top bar, things moved pretty easily. Only way to do it is to do it. I’ve done sculpture before, but I’ve never messed with straightening sheet metal ever. At first I roughed it in with a 2 1/2 lb hammer and then moved to hammer and dolly.

 

[Drake2]

I think I'm just afraid of that dreaded "C" word..................commitment. You're right though to get it done you've got to get it started.

 

[Drake2]

.

 

[BIGTOM]

I think I'm just afraid of that dreaded "C" word..................commitment. You're right though to get it done you've got to get it started.

I did a lot of reading and watching videos. Practiced welding sheet metal, and just jumped right in. Considering the small area, it’s not taking that much time.

 

[Drake2]

I did a lot of reading and watching videos. Practiced welding sheet metal, and just jumped right in. Considering the small area, it’s not taking that much time.

I started with a few of the "rust bubbles" and things were going ok until I found bondo above the rear wheels (outside) and it was like 1/2" deep until I hit metal. I was like WTF is going on here. Then I took a good size magnet to the rest of the body and there were not many places where it would stick . Stopped in my tracks right there, like dead stop. I know what I have to do, but not thinking about it is so much easier.

 

[BIGTOM]

I started with a few of the "rust bubbles" and things were going ok until I found bondo above the rear wheels (outside) and it was like 1/2" deep until I hit metal. I was like WTF is going on here. Then I took a good size magnet to the rest of the body and there were not many places where it would stick . Stopped in my tracks right there, like dead stop. I know what I have to do, but not thinking about it is so much easier.


View attachment 1972173

WOW!!! That’s some thick bondo! Have you tried to chip it out or remove more?

 

[bikersmurf]

I started with a few of the "rust bubbles" and things were going ok until I found bondo above the rear wheels (outside) and it was like 1/2" deep until I hit metal. I was like WTF is going on here. Then I took a good size magnet to the rest of the body and there were not many places where it would stick . Stopped in my tracks right there, like dead stop. I know what I have to do, but not thinking about it is so much easier.


View attachment 1972173

Once you are replacing a piece of metal, it doesn’t matter how big the holes in the middle of it are. Don’t let it intimidate you... you’ve more tools and resources at you disposal than the factory worker who first built it.

The rear 1/4s are mostly flat without any complex bends... you can easily defeat it. If you feel discouraged look up Michael’s thread, Rebuilding a 40 no longer in a single car garage. If an 18 year old version of me can build a 1/2 tub in the driveway with a torch and a sheet of steel... without even a grinder... you’re set. Jump in, and go for it.

 

[Drake2]

WOW!!! That’s some thick bondo! Have you tried to chip it out or remove more?

Yes, I started using a large flat blade screwdriver and a hammer to seperate the bondo from the metal. Chunks as big as 6" long have been popping off. I'm guessing the one of the PO's rolled it on it's side and just slapped 50 gallons of bondo and spray can paint before putting the for sale sign on it.

 

[dustinuhls]

Looks like crap. You should probably just ship it back to your buddy in Kansas so he can salvage some good sheet metal for his '75. You should also ask your friend out there if he has any decent doors that your buddy back in Kansas could use to make some 1/2 doors for his Land Cruiser!

 

[BIGTOM]

Looks like crap. You should probably just ship it back to your buddy in Kansas so he can salvage some good sheet metal for his '75. You should also ask your friend out there if he has any decent doors that your buddy back in Kansas could use to make some 1/2 doors for his Land Cruiser!

This time I have the Uhls Luck!!!