Build Jae's '01 LX modification documentation thread

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learning to try to remove a windshield without breaking it... not easy. either way, going to miss my "Easter egg" sticker (Etsy store that I got it from is "on break") ...
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... but, new driver mirror installed and fender mostly reshaped
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Got the windshield out and the truck put in a garage (going to be running a dehumidifier inside the cab to try and get the carpet dried out from the water intrusion from all the rain recently). I think the next step is going to be cutting off the outer skin on the pillar to see if it's possible to get the pillar bent back into shape or if it really is going to require fully replacing the whole structure.

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FWIW, the windshield removal was a total failure... part of that was probably that it was already broken and the wire cutter kept catching on breaks in the glass, but I have very little confidence that I would be successful on an un-broken windshield. At this point, just planning on ordering a new one rather than salvaging one.
 
door off, and starting on drilling out spot welds to get the outer skin off and see what I can do about this bent pillar

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found my a/c condenser fan relay and connector melted... so one more "while I'm here" issue to address.

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part numbers for relay, connector, terminals for my own reference
 
I tore into the pillar this weekend and got a lot of re-shaping done with a body hammer and dolly set... about ready to re-mount the door and start checking clearances and see how much more work needs to be done. Definitely leaning toward buying a replacement for at least one layer of this pillar so I can make sure that everything is back to the appropriate shape. going to start looking into options to get a cage around the front two rows to add some actual roll-over protection, especially after seeing the results of two roll-overs that were posted about on here just a few months ago.

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got a little more done, I really think it needs more shape. probably going to replace this section of the very inner layer so I have something of original shape to form the other layers to... we'll see. Still might just go get the entire pillar cut from the one that's local.

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using my gantry crane, a crescent wrench to bend flanges, and hammers, I've been working on getting the pillar back into shape. started by pulling with the crane while beating warped support metal back into shape, then reworking the flange into rough shape. made a shape template from the good side out of cardboard and used that to gage the appropriate curve, and will get the door put back on soon to gage from the inside.

got the good side cleaned up to make the shape gage,
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pulled with the gantry crane and chain hoist,
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roughly reshaped the flanges, (repeat step 2 and 3 a few times),
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... and looks like we're close.
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Keep in mind that there are two layers of sheet metal that will get welded back in. I'll get them clamped in place, remount the door, and check the door clearance before I start re-welding.
 
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