Mdej3
SILVER Star
Dammmzzz
Builds Inglorious B@sterd Build Thread
- Thread starter YMT
- Start date
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Saving an 80 from the junkyard; way to go. This project has my interest but we needs lots of pics. I think a pair of tons and those 40's would be perfect on this sort of build up. I'm sure you can get something for the 80 axles.
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- #23
Made some progress tonight. I hacked up the pillars from the original roof. I also cut a section of the roof (the only piece not bent) for scrap. I am going to cut the pinch welds off the pillars, and use them (in strips) as backing for me to weld the new roof on. They will also serve as guides when I lower the new (still used, but straight) roof.
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- #24
Here's the old roof that I cut off. I didn't get pictures of the middle section, from in front of the B pillar to in front of the C pillar.
Considering this 6k lb pig flipped over completely, and landed back on it's tires, it's really not all that much damage. Makes me feel good about a LC for family wheeling. I am also considering a cage, in the future, since I've hacked the pillars, and there's inherent weak points adjacent to welds. I'm undecided on interior or exterior cage at this time.
Considering this 6k lb pig flipped over completely, and landed back on it's tires, it's really not all that much damage. Makes me feel good about a LC for family wheeling. I am also considering a cage, in the future, since I've hacked the pillars, and there's inherent weak points adjacent to welds. I'm undecided on interior or exterior cage at this time.
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- #25
Yesterday, I started on the driver's side D pillar. I had cut around the base, then after looking closer, decided to cut above the inner structural brace.
Using the original pillar, seen 2 posts ago, I cut it into strips, trying to include as much of the factory bends for added strength.
After some drilling and rivets, here's the results. There's still a bunch of welding needed, but the braces added some strength.
I'm still undecided about how I am going to trim the pillars to match- since they are rounded off and slanted, lack reference points, and both the gold and blue pillars were cut hastily.
Using the original pillar, seen 2 posts ago, I cut it into strips, trying to include as much of the factory bends for added strength.
After some drilling and rivets, here's the results. There's still a bunch of welding needed, but the braces added some strength.
I'm still undecided about how I am going to trim the pillars to match- since they are rounded off and slanted, lack reference points, and both the gold and blue pillars were cut hastily.
A noble endeavor!
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- #27
Next I started on the driver's side C pillar. I had to trim and square about an inch off the blue pillar, to line it up with the original.
Then I cut up the C pillar scrap from a few posts ago.
Today I will drill and rivet the pieces into place on the driver's side C pillar
Then I cut up the C pillar scrap from a few posts ago.
Today I will drill and rivet the pieces into place on the driver's side C pillar
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- #28
Thanks!
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- #29
Well, I ran out of Dremel Saw Max cutoff disks, 4.5" angle grinder cutoff disks, and didn't want to mangle the pieces with the sawzall, so I had to cut my wrenching time short to resupply. I made a bit more progress. I trimmed the A,B, and C pillars on the roof, to butt up to the original pillars. After some pondering about the D pillars, I've decided I am not going to trim them to butt up; more on the D pillar later.
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- #30
Making more progress. Got the old pillars cut down into strips. Still need to trim the passenger side pillars on the roof to butt weld.
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- #31
More pictures of the strips
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- #32
Today I also noticed my first hurdle with this project, other than the obvious complexity of it. When I cut the A pillars, the passenger side, which was under tension from the torque, sprang back to it's correct, neutral position, relative to the door. The driver's side sprang back, however, not near as much as I expected it to, and there is a gap between the door and the pillar, which is causing alingment issues with the new roof.
I have tried sticking pipes, round stock, and even a T Post in the pillar to get the leverage to pull it back, close to the original position. I also tried to pull it with the pillar attached to an anchor (first a Deadman anchor, then my neighbor's tractor).
As you can see, the pillar needs to be moved down towards the door frame, and to the outside. I am seeking suggestions on how to do this. I do have the interior still installed, and so if it involves cutting then welding, I hope it's on the door side of the pillar, leaving the dash side to be what bends.
I have tried sticking pipes, round stock, and even a T Post in the pillar to get the leverage to pull it back, close to the original position. I also tried to pull it with the pillar attached to an anchor (first a Deadman anchor, then my neighbor's tractor).
As you can see, the pillar needs to be moved down towards the door frame, and to the outside. I am seeking suggestions on how to do this. I do have the interior still installed, and so if it involves cutting then welding, I hope it's on the door side of the pillar, leaving the dash side to be what bends.
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- #33
Well, I kept working on the driver's A pillar, and gave it some relief cuts in the sheet metal, and with a bunch of pressure, some strategic hammer hits, and a few choice 4 letter words, I was able to get it closer to where I want it. It's still not ideal and I will likely have to move it more when I butt weld the roof, but here's the results. I now have way more respect for body shop folks. There's some serious skills involved.
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- #34
I got the roof on! It was a royal PITA! I opted to slip the old D pillars into the D pillars of the roof- this is causing it to not sit all the way down- I will have to trim up the D pillars to butt up properly (it's about 1/4" up on all pillars). I know I keep flip flopping on this. I have tons of minor fitment work to do and then a ton more prep and welding.
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- #35
I had to cut out the pinch weld on the D pillar to get it to sleeve. This was a huge pain, since the pillars angle towards the center line of the vehicle. I had to use a strap to pull the roof pillars together, while also using a strap to my carport 4x4 post to pull the gold pillar to finally get it to slip in.
I've had to modify my plan from a few days ago. Now that I have the roof sitting close, I will cut off the portion of the gold pillars that I sleeved in, to get it ready to butt weld. I ran out of daylight today.
I've had to modify my plan from a few days ago. Now that I have the roof sitting close, I will cut off the portion of the gold pillars that I sleeved in, to get it ready to butt weld. I ran out of daylight today.
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- #36
Here's some pics of the guide strips I made from the old pillars. Since the A pillar is angled, I had to line it up first, then lower the roof in the rear, which was difficult without a second person.
Alright, I'll bite.
What the hell are you doing here? Do you plan on having OEM glass meet up with all of this? Are you like a welding genius?
I follow your posts religiously, but I just cannot understand how you think you are going to get this all back together.
Prove me wrong man, prove me wrong...
What the hell are you doing here? Do you plan on having OEM glass meet up with all of this? Are you like a welding genius?
I follow your posts religiously, but I just cannot understand how you think you are going to get this all back together.
Prove me wrong man, prove me wrong...
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- #38
First, I am not a welding genius. I used to be pretty good, but haven't welded in about a decade. I have some scrap panels laying around to work out the cobwebs.
I do intend to get the OEM glass to fit. The benefit to this project, assuming I don't botch up the windshield frame too bad, is worst case, I hack off the roof and just keep the A pillars, and have a pro weld it up.
Overall, my goal with this project is to get it trail-worthy (even road worthy); I know it won't win any beauty pageants, but that's not what I intend for it.
I have tons of fitment work to still do to get it even remotely ready for welding. Once I butt weld it, then I am going to add some sheet metal plates on the outside of the pillars. This is also mostly to keep the pillars from buckling during any flexing. I also will be fabbing a roll cage- I'm still undecided, but leaning towards an exo cage. I have a tendency to overbuild, and will do the same with this rig.
Ahh, got it. That makes more sense. I was trying to picture how it was going to work if you didn't eventually butt weld it. You have a project on your hands, that is for sure. I am impressed with your ambition!
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- #40
It's been a busy last few weeks so I thought I'd update this. About a month ago I got a job offer in CA, so I will be moving in a couple weeks. Finishing up home projects has taken priority, but I was able to get some progress done on the FJ. More pics coming soon. I have started welding the roof on, but it is taking far longer than I'd like to admit.
