Builds RevISK’s ‘80 FJ40 - A Girl Named Norman (3 Viewers)

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If anyone wants to see what hammered dog vomit looks like, here you go.
IMG_0212.webp


To be fair, this was what I had to work with:
IMG_0171.webp


The paint isn’t nearly that blue, flash sucks the life out of things.
 
EStein said:
That’s hardly hammered dog vomit. I think the repair looks great. Rust free in a place where no one will see! Now those other spots… I’ll say a prayer for you. 😁
Click to expand...
I’m going to need it, thank you.

Dug out my crappy old HF sheet metal brake, claims it’ll do 16g cold roll… we shall see.
I did a bunch of shapes with thickish anodized aluminum years back, remember only partially wanting to murder it so we’ll see.

The folded over parts will be interesting.
I’ll either try to fold them with a little heat and a lot of bang banging or back two together and burn a bead alongside the top.

I’m after the least seeable ones today, the parts that the above header was attached to.

A trick I learned from a prominent airstream restoration guy was that he’d dump a bunch of oil based paint inside the frame rails on big resto’s then take them for a twirl on the rotisserie.
I’ll do that with the header today as well, no rotisserie needed though.

Another fun spot with a folded edge.
IMG_0208.webp
 
wimberosa said:
keep the faith. all these look imminently doable. the rear door header patch looks great.
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Thank you. I’m tackling this nickel and dime stuff first so the larger, more visible and less complicated stuff will be my reward?
 
RevISK said:
I’m going to need it, thank you.

Dug out my crappy old HF sheet metal brake, claims it’ll do 16g cold roll… we shall see.
I did a bunch of shapes with thickish anodized aluminum years back, remember only partially wanting to murder it so we’ll see.

The folded over parts will be interesting.
I’ll either try to fold them with a little heat and a lot of bang banging or back two together and burn a bead alongside the top.

I’m after the least seeable ones today, the parts that the above header was attached to.

A trick I learned from a prominent airstream restoration guy was that he’d dump a bunch of oil based paint inside the frame rails on big resto’s then take them for a twirl on the rotisserie.
I’ll do that with the header today as well, no rotisserie needed though.

Another fun spot with a folded edge.
View attachment 3473490
Click to expand...
I’m not sure how perfect you want it to look, but I actually used angle iron in spots… Flush on the visible spots, not so much on the inside, but not visible. Specifically where that pillar just in front of the front doors meets the floorboards… Figured thicker gauge metal might not rust as fast. I had a cheap harbor freight metal brake and I couldn’t get it to bend 16 gauge… this isn’t a suggestion for you cause you are a better fabricator than me, but I would use angle iron for that whole patch. It would be about the thickness of where that pinch seam is. Two pieces together, you could make that whole wraparound. Weld it on the edge (blue) and then grind it to match the radius… is this sacrilege? Once you grind down the welds and paint, It would be pretty hard to see. And also less chance of blow through on those finicky spots. That being said, I used a lot of metal that I just had laying around my shop. I probably shouldn’t admit to some of my tactics in case I ever sell someday.

BD72AEA3-A42A-4169-9DB1-43C7B4663811.jpeg
 
Last edited:
I think the repairs look great so far. Gives me motivation to fix my hard top instead of replace.

It’s just time and a lot of Effort l.

Keep going
 
clrussell said:
I think the repairs look great so far. Gives me motivation to fix my hard top instead of replace.

It’s just time and a lot of Effort l.

Keep going
Click to expand...
Thanks bud.
Too much good on it to not fix it myself.
The floor pans will be a different story though…
Dragging donkey on that repair.
 
EStein said:
I’m not sure how perfect you want it to look, but I actually used angle iron in spots… Flush on the visible spots, not so much on the inside, but not visible. Specifically where that pillar just in front of the front doors meets the floorboards… Figured thicker gauge metal might not rust as fast. I had a cheap harbor freight metal brake and I couldn’t get it to bend 16 gauge… this isn’t a suggestion for you cause you are a better fabricator than me, but I would use angle iron for that whole patch. It would be about the thickness of where that pinch seam is. Two pieces together, you could make that whole wraparound. Weld it on the edge (blue) and then grind it to match the radius… is this sacrilege? Once you grind down the welds and paint, It would be pretty hard to see. And also less chance of blow through on those finicky spots. That being said, I used a lot of metal that I just had laying around my shop. I probably shouldn’t admit to some of my tactics in case I ever sell someday.

View attachment 3473646
Click to expand...
Very interesting, I’ll have a look and see what makes the most sense.

I’ve got two sheets of 16g cold roll here and a bunch of tools from my aluminum travel trailer days.

I really do get into the minutiae with stuff like this, I find the challenge entertaining.

Been fiddling with the 62 today and went on a cruise with the boy in Norman. Painting miniature animals with my daughter now.

Will probably dive into the welding once the first beer gets cracked… stupid daylight savings.
 
RevISK said:
Very interesting, I’ll have a look and see what makes the most sense.

I’ve got two sheets of 16g cold roll here and a bunch of tools from my aluminum travel trailer days.

I really do get into the minutiae with stuff like this, I find the challenge entertaining.

Been fiddling with the 62 today and went on a cruise with the boy in Norman. Painting miniature animals with my daughter now.

Will probably dive into the welding once the first beer gets cracked… stupid daylight savings.
Click to expand...
This is the repair I made with angle iron. You can feel it on the backside but on the front you’d never know. Definitely made welding easier. Blue line is about where the seam is. Not pure by any means!
Painting miniature animals! Excellent. Been there many times.

Edit.. actually the seam is a little lower than the blue line but you get the idea

B28E34A2-F458-4644-97C2-192B61D7237E.jpeg
 
EStein said:
This is the repair I made with angle iron. You can feel it on the backside but on the front you’d never know. Definitely made welding easier. Blue line is about where the seam is. Not pure by any means!
Painting miniature animals! Excellent. Been there many times.

Edit.. actually the seam is a little lower than the blue line but you get the idea

View attachment 3473799
Click to expand...
Well now, that’s legit.

I’ll look at what’s what with what and get a game plan.
I’ve continued to get side tracked on the 62 working on buttoning up the new front bumper.
Need to fab up a wench mount so I raided my neighbors scrap metal pile. Conveniently located at back property line just on the other side of the fence.

IMG_0213.webp
 
Overheard the camera guys talking about 3D printing. Casually strolled over with a print file I found online and asked if it would be possible to print one of these. Next morning was handed this. I painted the raised parts.

Not bad for free.
IMG_0243.webp
 
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