Restoring Green Bean '82 FJ40

[AdamKFarmer]

Thanks guys, I've never restored anything in my life and I have no welding experience. This probably won't progress at a fast pace. I bought a Hobart 220V welder and I have some promised help from a club member, so that will be interesting.

 

[subzali]

Way to go Adam!

Sent from my iPhone using IH8MUD at 85mph in an FJ40

 

[AdamKFarmer]

Way to go Adam!

Sent from my iPhone using IH8MUD at 85mph in an FJ40

Thanks Matt!

So a quick question. I was taking off these brackets last night and I don't think my hardtop has ever been fully disassembled. I was trying to pull this support off before I realized I need to take the top off first. Anyway, this weather stripping, is this 40-LH and 41-RH in this SOR diagram? http://www.sor.com/cat108.sor Any aftermarket places that have this?
Also, why is this area so rusted? What can I do to prevent this?

 

[SteveH]

Also, why is this area so rusted? What can I do to prevent this?

I am convinced that the only way to keep an FJ40 relatively rust-free is to not drive it in the winter in any area with salt, and to garage it. Every time condensate forms on the roof (in the summer at night), it runs down into the rain gutter, and then down all those cracks (like you showed) and they get wet. Multiply this time many years and you have some nasty rust issues. Even if you fill those cracks with a good putty or seam sealer before repainting, the sealer will eventually crack and you'll be back with cracks that are wet inside - promoting rust.

 

[AdamKFarmer]

A few pictures from my sunny Sunday workday
1) Progress so far - removed hardtop and most of the pieces from the rear
2) You can see where the PO painted the roll bar the wrong grey, I always thought it looked a little light, will be going back to the original color.
3) The top had been "restored" on the inside prior to my purchase. You can see where they painted over some rust. This will have to be patched.
4) More Rust
5) The rest of the top looks pretty good, just some paint and light sanding will do the trick.

 

[AdamKFarmer]

More pictures.
6) Hard top sides minus glass
7) Little surface rust along the rear brace
8) Again
9) Mig welding set up, started messing with flux core and gas shielded wire
10) The mig welder, so far so good. I do need 220 in the garage though.

 

[FrainTrain]

looks good man, lets weld the crap out of it and then ask questions later.

 

[subzali]

You going to remove whatever is on your rear crossmember too?

Sent from my iPhone using IH8MUD at 85mph in an FJ40

 

[AdamKFarmer]

Matt, yeah it's a large custom trailer hitch with a support going to the rear axle. I'm taking the grinder to it next.

 

[want2wheel]

Please make sure that you secure that bottle. Those can be very dangerous.

 

[AdamKFarmer]

Just bought some running gear, I'm assembling it tonight and will chain it down.

 

[AdamKFarmer]

Running gear operational!

...via IH8MUD app

 

[DTSkyCop]

Wow, love the progress and thread... Subscribed!! Keep up the good work!

 

[AdamKFarmer]

Little bit of progress made today. I think I might be able to get away with not replacing the entire bed. Just replace the rusted parts on the very edge.

...via IH8MUD app

 

[N919HJ]

I know nothing about metal or metal work, but don't you think it would be easier to cut the bed out as one piece and replace the whole thing. I have to think that if some parts are rusted through the rest isn't far behind. Is this the first time you have done any welding? It is a skill I would love to learn.

 

[AdamKFarmer]

Well, I'm teaching myself as I go. I've been told it isn't hard, after practicing on a bunch of scrap I can see how patching in metal is pretty straight forward. I think doing the small patches would be easier, smaller areas to weld and keeping the most original metal is a good thing. THe rest of the bed is in pretty good shape, some surface rust, but I am planning to get it blasted and then coat it with some good primer and paint, that should prevent the rest of the bed from rusting out. Just buy a welder and get started! That is what I was told!

 

[AdamKFarmer]

A little work done this weekend. I cut off the monstrosity of a tow hitch that was welded to the frame. I might cut off the tail and re-install it, but jury is still out on that. It was pretty rust and the PO made swiss cheese out of my rear cross member. I can't tell how many extra holes there are, but I think at least 4. Hard to see in these pictures but I found a rust hole in my rear sill, I think it's around the drain hole? Not 100% sure if that's correct but it looks like a round oval that is rusted out.

 

[subzali]

Wow, didn't ever notice that rear hitch. Glad you got rid of that.

Sent from my iPhone using IH8MUD at 85mph in an FJ40

 

[AdamKFarmer]

Wow, didn't ever notice that rear hitch. Glad you got rid of that.

Sent from my iPhone using IH8MUD at 85mph in an FJ40

It was a beast. The mechanic who inspected the 40 prior to my purchase told me to never let anyone talk me out of that hitch, it is bullet proof. It is overkill for sure, I've never towed anything heavier than my road bike, if I had to do something heavy I would use the 4Runner.

 

[AdamKFarmer]

Finally removed the bedliner from the floor of the Bean. I just have the PS wheel well and the sides of the tub to go. Quick question. I have some dents and you can see that the tops of my wheel wells are dented in. What could I do?

...via IH8MUD app