Love it! It doesn't always make sense, but sometimes it's just what's needed. And then the light
goes on.
New to FJ55s. . .
- Thread starter Tom FJ55
- Start date
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Love it! It doesn't always make sense, but sometimes it's just what's needed. And then the light
goes on.
- Thread starter
- #262
Little update. . . I've had 2 of the most physically hard days working on the 55 yet. I started on the roof & the interior and most of my time was spent scraping the old matting and glue off the underside of the roof - what a gnarly undertaking. I can barely lift my arms over my head! Holding either the electric oscillating tool (which worked great) or the grinder over my head for 2 days while kneeling or sitting on a milk crate inside the 55 just about did me in. I'm really happy with how it turned out, but boy, it was a lot of work.
It's hard to tell from the pics, but the roof was really munched in and pretty wavy. I laid on my back inside on the floor and used my feet & legs to push the major dents/waves out. It's not perfect, but it's way better. I think adding an extra support or 2 back in will help it keep it's shape.
I decided to cut out the 2 roof supports and I'm glad I did. It was easy to grind the welds and get them out, and it made it soooo much easier to clean up the underside of the roof w/out them in the way. It would've been impossible w/them in there. I'm not sure what I'm going to replace them with - mine are pretty bent up. I have a few ideas, but need to do some head scratching and investigating.
I had to take breaks to allow my arms to recover a bit, so I've been popping off the interior door panels and lubing the opening/closing mechanisms, the locks and the window regulators. 2 of 4 now work really well, nice and smooth.
Here's a few photos of what I started with inside & outside, some of the tools of choice.
It's hard to tell from the pics, but the roof was really munched in and pretty wavy. I laid on my back inside on the floor and used my feet & legs to push the major dents/waves out. It's not perfect, but it's way better. I think adding an extra support or 2 back in will help it keep it's shape.
I decided to cut out the 2 roof supports and I'm glad I did. It was easy to grind the welds and get them out, and it made it soooo much easier to clean up the underside of the roof w/out them in the way. It would've been impossible w/them in there. I'm not sure what I'm going to replace them with - mine are pretty bent up. I have a few ideas, but need to do some head scratching and investigating.
I had to take breaks to allow my arms to recover a bit, so I've been popping off the interior door panels and lubing the opening/closing mechanisms, the locks and the window regulators. 2 of 4 now work really well, nice and smooth.
Here's a few photos of what I started with inside & outside, some of the tools of choice.
- Thread starter
- #263
These pics show what I accomplished after day 1, the final all clean roof, and the 1 rust hole I've found so far that needs a patch.
The rust hole is in the driver's side floor board, right near what I'm assuming is the body mount? It was a small hole, maybe as big as a quarter that I had to hit w/a wire wheel to uncover. I cut it open and the entire inside was PACKED w/fine dirt/sand. I cleaned out the interior, cleaned up the hole and will weld a patch over it the hit it w/some POR15 - my rust paint of choice. I also plan to paint over a few other spots on the floor that are showing some rust - some big scale, but no other holes yet. . . hopefully that will at least slow the cancer down a bit.
One other thing I did yesterday is remove all the door body mouldings. I did this because they were pretty rotted and so I could remove all the remnants of headliner and door pillar trims and also see the flanges at the bottom which are a bit rusty. I cleaned them all up and they'll get POR15'd, then new door body mouldings from SOR most likely.
I spent a few hrs. going through the weatherstripping thread last night trying to get a handle on the options. I did some copy and pasting into a Word document to keep a running tab on the latest suggestions as I read through all 30 pages. Unfortunately, my computer f'ing locked up when I went to save it, so it's gone - major bummer! I did have some questions on that, but I need to take a break as I'm still pi$$ed about losing a few hrs. of work last night!
Anyway, here's more pics:
The rust hole is in the driver's side floor board, right near what I'm assuming is the body mount? It was a small hole, maybe as big as a quarter that I had to hit w/a wire wheel to uncover. I cut it open and the entire inside was PACKED w/fine dirt/sand. I cleaned out the interior, cleaned up the hole and will weld a patch over it the hit it w/some POR15 - my rust paint of choice. I also plan to paint over a few other spots on the floor that are showing some rust - some big scale, but no other holes yet. . . hopefully that will at least slow the cancer down a bit.
One other thing I did yesterday is remove all the door body mouldings. I did this because they were pretty rotted and so I could remove all the remnants of headliner and door pillar trims and also see the flanges at the bottom which are a bit rusty. I cleaned them all up and they'll get POR15'd, then new door body mouldings from SOR most likely.
I spent a few hrs. going through the weatherstripping thread last night trying to get a handle on the options. I did some copy and pasting into a Word document to keep a running tab on the latest suggestions as I read through all 30 pages. Unfortunately, my computer f'ing locked up when I went to save it, so it's gone - major bummer! I did have some questions on that, but I need to take a break as I'm still pi$$ed about losing a few hrs. of work last night!
Anyway, here's more pics:
- Thread starter
- #264
End of the week update. . .
Today I finished some light sanding and prep work so I could paint the interior - just the sides as the roof is getting carpet and the floor still needs some light welding/patching before getting POR15'd. Most of the prep work was in masking off. I kept it pretty simple, but it looks pretty good. Hopefully it'll last at least for a bit. . . we'll see.
I had a few more pics of the prep, but my wife swiped the camera part way through the day and erased them. . . look at the previous post for "before" pics!
Next up is welding on the floor, POR15 on the floor and carpet on the roof. . . then we ride!
Today I finished some light sanding and prep work so I could paint the interior - just the sides as the roof is getting carpet and the floor still needs some light welding/patching before getting POR15'd. Most of the prep work was in masking off. I kept it pretty simple, but it looks pretty good. Hopefully it'll last at least for a bit. . . we'll see.
I had a few more pics of the prep, but my wife swiped the camera part way through the day and erased them. . . look at the previous post for "before" pics!
Next up is welding on the floor, POR15 on the floor and carpet on the roof. . . then we ride!
Nice job on the roof, that glue is some tough stuff. Hardest thing I've done so far.
- Thread starter
- #266
Little post-weekend update. . .
The rust hole in the driver's floorboard grew as I poked and prodded further (of course!). I probably could've/should've cut out a much bigger piece, but I tried to keep it manageable. There is still some structure to what I left, but it is definitely thin in spots and not easy to weld to in others. I feel a bit guilty for not digging deeper, but I decided to draw the line. While it's in great overall shape, I don't have any ambitions for the 55 other than a fun, around town beater so it doesn't have to be perfect - that's my rationalization at least. I can always go back and replace bigger sections later. . .
So the interior sides are painted, rust/hole patches are welded in, the floor is spot-POR15'd, the roof is ready for carpet and new supports. . . I also finished popping off all the door panels and lubing the locks and opening mechanisms - they all operate like butter now, very nice!
Just about to put in what is hopefully my last big parts order for a while - door body mouldings, a plastic dash cap cover and a few misc. little pieces. . .
Here's a few pics: one of how nice the newly painted sides look next to the tailgate which I didn't paint, and a few of the spot-POR15'd floor - decided to go w/gray as that's what I had the most of. It'll be covered up by the mats anyway.
The rust hole in the driver's floorboard grew as I poked and prodded further (of course!). I probably could've/should've cut out a much bigger piece, but I tried to keep it manageable. There is still some structure to what I left, but it is definitely thin in spots and not easy to weld to in others. I feel a bit guilty for not digging deeper, but I decided to draw the line. While it's in great overall shape, I don't have any ambitions for the 55 other than a fun, around town beater so it doesn't have to be perfect - that's my rationalization at least. I can always go back and replace bigger sections later. . .
So the interior sides are painted, rust/hole patches are welded in, the floor is spot-POR15'd, the roof is ready for carpet and new supports. . . I also finished popping off all the door panels and lubing the locks and opening mechanisms - they all operate like butter now, very nice!
Just about to put in what is hopefully my last big parts order for a while - door body mouldings, a plastic dash cap cover and a few misc. little pieces. . .
Here's a few pics: one of how nice the newly painted sides look next to the tailgate which I didn't paint, and a few of the spot-POR15'd floor - decided to go w/gray as that's what I had the most of. It'll be covered up by the mats anyway.
PabloCruise
SILVER Star
Nice Tom!
You are tearing it up!!!
You are tearing it up!!!
- Thread starter
- #268
Thanks Pablo; trying to do the literal opposite of "tearing it up" at this point!
Still trying to figure out what to do for roof supports. I have a few ideas and made a cardboard template of the roof profile yesterday to start with. . . not 100% sure on my direction yet though.
Also been trying to visualize how in the heck I'm going to be able to cut to fit & glue 1 enormous piece of carpet to the roof. I bought some high $$ 3M high-strength headliner spray adhesive, but sitting solo under a pile of carpet methinks will be tricky. I may need to enlist help for that one. . .
- Thread starter
- #269
Big day! Headliner is in! It took a little head scratching and a big leap of faith, but the end result looks pretty good I think - I'm happy with it. Having something on the roof lessens the tin can effect by a large amount too, which is nice.
It was a bit of a struggle as a 1-man operation, but with some jimmying etc... it was doable. After cutting the carpet to fit width-wise, I drew a line down the center of it and a matching line down the center of the underside of the roof. Because the carpet has ribs/lines, one thing I was nervous about was having them be wavy or angled when you looked down the entire thing from the tailgate. Having the lines to match up was a BIG help. Even though I strayed by about 1" from front to back, it's not something that's noticeable - at least to me. There are a few sections that I could unglue and restretch because of small wrinkles etc... and I may do that if I get motivated - just not right at the moment.
A friend came by and made an excellent suggestion - to put some "U" channel black welting around the metal lip at the top. That's on my long term list as I think it will finish off the roof well.
Here's some pics of the process:
I used a sawhorse at the beginning to support the roll; I started at the back and worked my way to the front. First finished corner looks good!
It was a bit of a struggle as a 1-man operation, but with some jimmying etc... it was doable. After cutting the carpet to fit width-wise, I drew a line down the center of it and a matching line down the center of the underside of the roof. Because the carpet has ribs/lines, one thing I was nervous about was having them be wavy or angled when you looked down the entire thing from the tailgate. Having the lines to match up was a BIG help. Even though I strayed by about 1" from front to back, it's not something that's noticeable - at least to me. There are a few sections that I could unglue and restretch because of small wrinkles etc... and I may do that if I get motivated - just not right at the moment.
A friend came by and made an excellent suggestion - to put some "U" channel black welting around the metal lip at the top. That's on my long term list as I think it will finish off the roof well.
Here's some pics of the process:
I used a sawhorse at the beginning to support the roll; I started at the back and worked my way to the front. First finished corner looks good!
Very nice job.....looks fantastic!
Tom,
Good job on the roof! I have to do something to mine, also. Are you putting the supports back in and dome light.
Ron
Good job on the roof! I have to do something to mine, also. Are you putting the supports back in and dome light.
Ron
Nice work Tom.I just rolled into Ketchum,I would love to come bye and check out the rig if you are around this weekend.
Matt
Matt
- Thread starter
- #274
Hi Ron -
Yes, I am planning on adding some supports; I think the roof would cave right back in if there was any weight placed on it (ie:snow). I'm still tossing around a few different ideas on what to do up there - planning to fabricate something instead of using stock bars.
Nice work Tom.I just rolled into Ketchum,I would love to come bye and check out the rig if you are around this weekend.
Hi Matt - I don't have any plans this weekend as far as I know (need to check w/the family to verify!). . . I'll PM you my email address so we can swap phone numbers.
Nicely Done Tom
Hey All,
The progress Tom has made on his Pig has been amazing to watch. I have the benefit of being able to stop by his house & check on things periodically & it looks even better in person. I thought the body on my '75 55 was respectable, but his has set a new standard for rot free (it's all relative right?). The fact that it was like hat after all those years outdoors blows me away.
I have been a lurker on Mud for years now & have owned my Pig for 5 years but iit wasn't until I saw how amazing the members have been to Tom that I realized I needed to get involved.
Kudos to all of you for the support you offer those of us who struggle through the basics of keeping these great trucks on the road.
And, to stay on topic: Tom I do have some of that pinch molding left over. If we can connect tomorrow don't let me forget to hand it over.
Best,
Nick
Hey All,
The progress Tom has made on his Pig has been amazing to watch. I have the benefit of being able to stop by his house & check on things periodically & it looks even better in person. I thought the body on my '75 55 was respectable, but his has set a new standard for rot free (it's all relative right?). The fact that it was like hat after all those years outdoors blows me away.
I have been a lurker on Mud for years now & have owned my Pig for 5 years but iit wasn't until I saw how amazing the members have been to Tom that I realized I needed to get involved.
Kudos to all of you for the support you offer those of us who struggle through the basics of keeping these great trucks on the road.
And, to stay on topic: Tom I do have some of that pinch molding left over. If we can connect tomorrow don't let me forget to hand it over.
Best,
Nick
PabloCruise
SILVER Star
Nice comments Nick!
Welcome to the fold...
Welcome to the fold...
- Thread starter
- #277
Yes, thanks Nick for the nice words!
I stopped by Nick's house today to take a look at his 55 and it's NICE! Mechanically top notch in every way, but w/some minor rust issues that Nick is addressing. Hopefully he'll start a thread on it w/lots of pics.
I spoke to Matt (Sawtooth 55 LC) on the phone today but unfortunately we weren't able to connect - hopefully next time!
I WAS going to take a break from working on the 55 for a while and just drive it. . . but I can't help myself. Right now I've got the entire dash, pulled apart and gauge cluster out. I spent some time chasing a few niggling electrical issues (non-op fuel level gauge etc...) and am right in the middle of putting a plastic cover over the dash. My original dash was in really tough shape, so I decided to pull it out completely and fill all the cracks w/epoxy to create a nice stable foundation for the cap. A bit of work, but I think it'll look good in the end. Hopefully after I've got the dash back together, I can leave it alone for a bit. . . except for a quick tune up/valve adjust, change the trans. & diff. fluids & adjust the drum brakes which are pulling to the right. . . : ) : )
Hope everyone had a great weekend!
Really wanted to see your rig Tom and all the great work you have done to it.Due to poor planning on my part and a couple of sick humans we made a straight shot home.I will be back up soon and will definitely get over to see your 55 and your buddy's in town as well.Happy Cruisin'
A couple of Cruiser's spotted on our way the the hot springs.2 of many spotted over the weekend.
A couple of Cruiser's spotted on our way the the hot springs.2 of many spotted over the weekend.
Tom let me sit in it...
Hey All,
Tom and I had to meet to day on actual work related stuff. In true OCD Pig-Owner fashion we managed to spend more time talking about our trucks then any time we spent on the job. I might even be able to bill our client as we were waiting for her interior designer to call...
I did get a chance to sit in his Pig & fire it up. Instant gratification and it sounds great. He also just wrapped up a dash refurbishment that looks killer & should be appropriately documented (hint) His truck is really looking amazing and has that "sleeper" look to it. Faded paint and all stock, but an engine that grunts right along. Great work.
In addition, Tom (& the rest of you guys) has gotten me motivated to work on mine. Did a full lube, oil, filter, & carb clean tonight. Sounds better than ever. Even got my son to help as he is going to be driving it soon. Way more fun to take pics of him yanking on the drain plug than doing it myself. I am going to chip away at some posts so I can start a thread of my own. Want to wait until I have pic capabilities as one of the first orders of business will be posting some images and soliciting some advice/direction.
Thanks for letting me crash the party Tom.
Nick
Hey All,
Tom and I had to meet to day on actual work related stuff. In true OCD Pig-Owner fashion we managed to spend more time talking about our trucks then any time we spent on the job. I might even be able to bill our client as we were waiting for her interior designer to call...
I did get a chance to sit in his Pig & fire it up. Instant gratification and it sounds great. He also just wrapped up a dash refurbishment that looks killer & should be appropriately documented (hint) His truck is really looking amazing and has that "sleeper" look to it. Faded paint and all stock, but an engine that grunts right along. Great work.
In addition, Tom (& the rest of you guys) has gotten me motivated to work on mine. Did a full lube, oil, filter, & carb clean tonight. Sounds better than ever. Even got my son to help as he is going to be driving it soon. Way more fun to take pics of him yanking on the drain plug than doing it myself. I am going to chip away at some posts so I can start a thread of my own. Want to wait until I have pic capabilities as one of the first orders of business will be posting some images and soliciting some advice/direction.
Thanks for letting me crash the party Tom.
Nick
- Thread starter
- #280
Thanks to Nick for motivating me to post some pics of the dash. I'm getting to the point where I need a break from working on it and just wanted to get the dash done, so that's why my motivation was low and I'm a bit short on pics. . .
I started by troubleshooting the fuel level and temp gauges, neither of which were working. I pulled the fuel level sender, cleaned it up, checked that there were no shorts in the wiring to the gauge etc... By the end, I'd completely removed the glove box, main dash pad and the gauge cluster/pod. I took the gauges apart and gave them a full cleaning. The part of the dash that hold the gauges was haggared too, so I glued all the vinyl back around the openings and filled in some gaps w/epoxy & some body filler etc.... Then gave the whole thing a few coats of primer and then a few coats of semi-matte black. It looks brand spanking new!
The dash had about 10 major cracks through it which I filled w/epoxy, then sanded down the high spots. I bought a plastic dash cover which required a good deal of trimming in the center to fit. I think the later 55's have a different center section where the back window switch is located. It was hard to cut up a brand new dash cover, but it doesn't look too bad.
In the end, I'm totally happy w/how it all turned out. All the spots on the interior I've touched up really make the spots I haven't touched up stand out!
I'm going to try to stop working on it for a bit so I can catch my breath and give my check book a break too. I'm happy w/where it is at the moment - reached my immediate goal of getting it safe, drivable, somewhat habitable and back on the road and by some minor miracle, I've reached my budget number at the same time!
So after I change the trans./transfer case/diff. fluid this weekend and give it a quick tune up again, I'm hoping to stop for a while. . . but know I probably won't be able to! There's still the matter of the interior rear panels, fabricating a cool rack, touching up the exterior and the rust on the roof, ohhhh and I found a 2F and 4spd. trans. that's only 1 1/2 hrs/ away from me that's fore sale. . . : ) : )
IT WILL NEVER END! But that's OK.
A few "before" pics of the dash first, then a few "after" pics.
I started by troubleshooting the fuel level and temp gauges, neither of which were working. I pulled the fuel level sender, cleaned it up, checked that there were no shorts in the wiring to the gauge etc... By the end, I'd completely removed the glove box, main dash pad and the gauge cluster/pod. I took the gauges apart and gave them a full cleaning. The part of the dash that hold the gauges was haggared too, so I glued all the vinyl back around the openings and filled in some gaps w/epoxy & some body filler etc.... Then gave the whole thing a few coats of primer and then a few coats of semi-matte black. It looks brand spanking new!
The dash had about 10 major cracks through it which I filled w/epoxy, then sanded down the high spots. I bought a plastic dash cover which required a good deal of trimming in the center to fit. I think the later 55's have a different center section where the back window switch is located. It was hard to cut up a brand new dash cover, but it doesn't look too bad.
In the end, I'm totally happy w/how it all turned out. All the spots on the interior I've touched up really make the spots I haven't touched up stand out!
I'm going to try to stop working on it for a bit so I can catch my breath and give my check book a break too. I'm happy w/where it is at the moment - reached my immediate goal of getting it safe, drivable, somewhat habitable and back on the road and by some minor miracle, I've reached my budget number at the same time!
So after I change the trans./transfer case/diff. fluid this weekend and give it a quick tune up again, I'm hoping to stop for a while. . . but know I probably won't be able to! There's still the matter of the interior rear panels, fabricating a cool rack, touching up the exterior and the rust on the roof, ohhhh and I found a 2F and 4spd. trans. that's only 1 1/2 hrs/ away from me that's fore sale. . . : ) : )
IT WILL NEVER END! But that's OK.
A few "before" pics of the dash first, then a few "after" pics.
