Nut & Bolt Frame-Off 1978 FJ40 Restoration

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110V, and again, I'm using flux core, so I realize I am a bit limited. I'm doing stitch welds to try and keep heat down.

Are you using the machine's recommended settings for sheet metal? That should get you close. Also, flux core will not be the easiest for sheet metal work.
 
I think you can get the penetration you need with your stitch welds. Your welding thin metal and not 11gauge or thicker. I welded some small holes on my FJ40 with a metal rod, cut off the extra, sanded the rest down and looks great. That was after a burn through so I did the practice thing. It seems like your on the right track, especially doing stitch welds the most important thing,,,patience. This was me when first started welding thin metal.:bang:. Your doing a good job, good luck.
 
Making progress. I know gas would make things easier but...it looks like i can get away with not using it just yet.
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Started looking at this "liner" and realized that it was worthless, and rotten. I decided to start chipping it away to make sure I didn't have anything nasty hiding underneath it.
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So far so good
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Found some rust holes. Bummer.
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And another crack near the door sill
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Pulled out the welder and got to work
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Got some burn-through with this one. Im going to have to slowly weld this one to build up material. This is a learning process; granted the metal here was paper thin from rust.
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Rust bullet in that tub will self level/protect/ dry hard as nails but still show metal shape (not a bedliner)

It will fill in those small rust holes.
 
Dry ice works great for removing the spray on coating
 
Yes, the Rust Bullet will be great on the pitted floor. For that burn through, I would patch from the bottom side and weld from the top, like a rosebud weld. You should use 3M weld through to spray on to protect the metal from the bottom. That's just something I've done and work great. However, there are bigger brains out there that may have a better solution.
 
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No s***. This is taking FOREVER!
 
So those who have used Rust Bullet:

Do I apply it over bare metal, or can I apply it over paint?
 
So those who have used Rust Bullet:

Do I apply it over bare metal, or can I apply it over paint?

It CAN be applied over paint but its ideal adhesion is over rusty/pited metal. Take off what paint you can and roll on 2 thick coats of RB and its rock solid.

Make sure to put tape in the roll cage and seat frame captive nuts!!!!
 
Strong work. I'd wear a mask and goggles while scraping that stuff. It is supposedly Navy grade aircraft carrier liner so probably not good for your health.
 
Strong work. I'd wear a mask and goggles while scraping that stuff. It is supposedly Navy grade aircraft carrier liner so probably not good for your health.

Can't be any worse for you than Aircraft Paint Remover. Warning label on that stuffs says, Can Cause Genetic Mutations.
 
Or the zinc primate (chromate) paint we used as rust inhibitor back when I was in. Nasty stuff
 
New grade 8 hardware installed
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Pulled out the seat brackets for the driver's seat. Wire wheel, then black epoxy paint.
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Then took apart the driver's seat hardware. Wire wheel, then black epoxy.
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Then reassembled with new stainless hardware
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Turd polishing:
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New emblems and bumperettes from CCOT. Also made a little bracket to hold the plate in place.
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