Builds My 78' Barn find FJ45 (3 Viewers)

[bikersmurf]

Aqualu does make new frames, but I think you've got things under control.

The 45 I parted out had nothing left of most of the frame... It couldn't have been repaired.

 

[Michael B]

Thanks for the input smurf. I thought someone was making them but couldn't remember who. Did your frame require any work up before installation?

 

[Michael B]

I completed the Saginaw upgrade this evening. I'm pleased with the installation. All of the welding on this modification is courtesy of Roma. Thanks buddy!!

 

[Michael B]

I took a break from working on the 45 today and made some wall art with the left over pieces. Now I just need to find a place to hang it.

 

[Michael B]

Last Friday I dropped the frame off for sandblasting. I spent the holiday weekend prepping my old axles to sell. I also spent Sunday afternoon helping Roma with a 5 speed and t case he is selling.

Today I picked up my sandblasted frame (sorry no pics yet, it was raining when I arrived home) and Friday I'm taking it to Chattanooga for galvanizing.

 

[Michael B]

I finally made it to the galvanizer!

 

[Varty Yo]

Wow did i missed alot!

Never knew you were going frame off with this. Fully subcribed now!!!

 

[Michael B]

Thanks Brett. Hopefully you've tuned in for the good part. I'll spend this weekend drilling and tapping holes and then deliver the frame for paint on Monday.

 

[Michael B]

I dropped my frame off at the body shop for painting today and snapped this pic of the bed being test fit with new floor.

 

[Michael B]

I brought the frame home from the paint shop today. Other work that has been accomplished; the bed floor is now tacked in place and the rear sill has been replaced. The cab has been completely disassembled and the cowl has been removed in preparation for the LHD cowl install. Both pieces should be sand blasted tomorrow.

 

[Dagha Boy]

Looking really good! Any chance of posting some pics of the work being done on the cowl? Or a description of the procedure?

 

[Michael B]

Dahga regrettably I did not get pictures of the cowl removed. The process is rather simple in theory. There is a factory seam where the cowl meets the tub on all 40 series rigs. There are 2 bolts on each side where the rocker panel meets the A pillar (one is underneath the body). These are removed. Then at that same joint there is a solid weld on each side that would need to be removed. After that there are 6-8 spot welds across the floor pan on each side to be removed. Then the cowl is free and ready to be removed. The installation is the reverse. This is a very basic over view, the actual execution is pretty labor intensive. I would not recommend this if you were planning on removing the cowl and reinstalling it on the same vehicle. As one side or the other (the rockers or the cowl) will not be useable after this removal process is complete. One side has to be sacrificed during the removal process.

I hope this helps.

 

[Michael B]

I disassembled the rear axle today. It's ready for a little grinding, blasting and paint.

 

[Michael B]

I was able to blast and paint the axle housing today. The backing plates are blasted and I'll paint them tomorrow after work if it's not raining.

 

[Michael B]

@dahga boy here are some pictures of the old cowl after it was removed. Notice my body man got tired of the slow tedious process of cutting away the weld and took a plasma cutter to the old cowl and then he ground the remnants away from the tub. Which is much quicker!!

 

[Dagha Boy]

Thanks for all your trouble. Just got back home and checked e-mail...

That's fairly major surgery! As I understand it, it is now a matter of welding the LHD cowl to the rockers and floor of the remains of the pick up tub?

What I have had in mind was to take off the dash panel and the firewall from under the cowl to the bend where the firewall bends Out of a rusted out LHD tub. My thinking was to be able to do it one piece at a time - 1st the RHD dash off and then immediately weld the LHD dash in place - 2nd remove the RHD firewall and then immediately weld the LHD firewall in place. All of this with the tub bolted to the frame... getting the door openings right is my big fear.

Your frame and axles looking real good. The nice part of the job is on hand. Time to pull on the white gloves and start assembly.

 

[cult45]

Thanks for all your trouble. Just got back home and checked e-mail...

That's fairly major surgery! As I understand it, it is now a matter of welding the LHD cowl to the rockers and floor of the remains of the pick up tub?

What I have had in mind was to take off the dash panel and the firewall from under the cowl to the bend where the firewall bends Out of a rusted out LHD tub. My thinking was to be able to do it one piece at a time - 1st the RHD dash off and then immediately weld the LHD dash in place - 2nd remove the RHD firewall and then immediately weld the LHD firewall in place. All of this with the tub bolted to the frame... getting the door openings right is my big fear.

Your frame and axles looking real good. The nice part of the job is on hand. Time to pull on the white gloves and start assembly.

Dahga find yourself a curved firewall brace whilst still in the US of A, then go home and spot weld it in, then cut out the steering column hole and the heater hole and swap them over. Then drill out the spot welds holding in the dash panel and swap that over [or cut out the glove box lid area and the speedo cluster area] and replace. That way you'll keep all the structure of the cowl in place and it'll stay square.

 

[Michael B]

I've been working on refurbing the rear axle this week. Blasting and painting the smaller parts. Most of my new parts are here. The bearings and seals came from Georg at Valley Hybrids. The brake hardware and wheel cylinders came from Rock Auto. Notice that at RC Advics equals Aisin @$21.79 ea.

 

[Jespervangfalkenberg]

Wow - looking really good! You will be SO happy to do it the right way

Thumbs up buddy

 

[Michael B]

Thank you Jesper. Just trying to make the truck ready for the next 20 years.