Well, getting near the end of nephew Zach's 40 project: Project FJ By 16 year old and Schmukster and have run into a few problems that have me stumped. Looking for help/advice, someone telling me that I did something dumb and how to re-do it, etc. Any input helpful.
The truck started as a 77- still has the original frame and engine that came with the project that had been completely disassembled when we got it. I had found a rebuilt tub in Alabama at a good price and Jim and Zach went down to pick it up. The tub is from a 72 or 73. The tub fit just fine onto the 77 frame. The rear of the tub at the door openings were modified by welding in the inserts to make the ambulance doors fit properly. Yes the truck uses Amby doors and newer style front doors. Windshield frame is from a 73. The hardtop sides are from the 77 as is the fiberglass top.
Got the hardtop sides mounted, rear door opening header bar installed and amby doors mounted and fitting just fine, used OEM weatherstripping. When i went to install the front doors I found that they didn't want to fit well at all. The top rear corners of both doors were leaning backwards subsrtantially. The passenger side was closer in fit than the driver side, we got it to fit pretty well by elongating the slots in the upper door hing (the side of the hinge that bolts to the door itself). To get a good fit at the upper front corner we had to recline the windshield back further than it normally would be- that is the original spacers that the WS locking knobs go through are now too long to fit in their original location.
The driver door is out of whack further than the passenger side and elongating the slots in that door hinge don't give ius enoughh room. Even with the front edge of the driver side door butting up against the half of the door hinge that attaches to the cowl the door is still way out of adjustment. Yes we have looked at some ideas to make this door fit but then we found the problem that really has me stumped.
When we set the already painted top onto the truck there is a gap almost 1" between the bottom of the top (the attaching lip) and the front of the hardtop side. See the pics to underside just what the heck I am talking about. These two photos show a black straightedge laid along the top from the rear corner of the hardtop side to the WS area where the front door header mounts
The second photo also illustrates how far out of adjustment the door is. This photo shows how far forward I have already moved the door in it's upper hinge- the front edge of the door hits the half of the hinge that is attached to the cowl.
We tried a lot of different fixes- replaced these hardtop sides with another set I have, same result. tried an older style front door- same misalgnment. I compared the dimensions of the older style windshield frame we're using to a newer style WS frame i have and the height looks to be the same.
What the hell am I missing here? Looking for a workable answer and am hoping the tub wasn't welded together incorrectly when the previous owner re-did it. Help! I'm sick about this- so close to the end and now this. Agaian any input is appreciated. Thanks in advance. Gary S
The truck started as a 77- still has the original frame and engine that came with the project that had been completely disassembled when we got it. I had found a rebuilt tub in Alabama at a good price and Jim and Zach went down to pick it up. The tub is from a 72 or 73. The tub fit just fine onto the 77 frame. The rear of the tub at the door openings were modified by welding in the inserts to make the ambulance doors fit properly. Yes the truck uses Amby doors and newer style front doors. Windshield frame is from a 73. The hardtop sides are from the 77 as is the fiberglass top.
Got the hardtop sides mounted, rear door opening header bar installed and amby doors mounted and fitting just fine, used OEM weatherstripping. When i went to install the front doors I found that they didn't want to fit well at all. The top rear corners of both doors were leaning backwards subsrtantially. The passenger side was closer in fit than the driver side, we got it to fit pretty well by elongating the slots in the upper door hing (the side of the hinge that bolts to the door itself). To get a good fit at the upper front corner we had to recline the windshield back further than it normally would be- that is the original spacers that the WS locking knobs go through are now too long to fit in their original location.
The driver door is out of whack further than the passenger side and elongating the slots in that door hinge don't give ius enoughh room. Even with the front edge of the driver side door butting up against the half of the door hinge that attaches to the cowl the door is still way out of adjustment. Yes we have looked at some ideas to make this door fit but then we found the problem that really has me stumped.
When we set the already painted top onto the truck there is a gap almost 1" between the bottom of the top (the attaching lip) and the front of the hardtop side. See the pics to underside just what the heck I am talking about. These two photos show a black straightedge laid along the top from the rear corner of the hardtop side to the WS area where the front door header mounts
The second photo also illustrates how far out of adjustment the door is. This photo shows how far forward I have already moved the door in it's upper hinge- the front edge of the door hits the half of the hinge that is attached to the cowl.
We tried a lot of different fixes- replaced these hardtop sides with another set I have, same result. tried an older style front door- same misalgnment. I compared the dimensions of the older style windshield frame we're using to a newer style WS frame i have and the height looks to be the same.
What the hell am I missing here? Looking for a workable answer and am hoping the tub wasn't welded together incorrectly when the previous owner re-did it. Help! I'm sick about this- so close to the end and now this. Agaian any input is appreciated. Thanks in advance. Gary S
