Rolling rebuild and dumb questions

[Bambi Girl]

Hi micdon
My mother once told me its a sad day when you don't learn something .
Well I was a bit worried because I did not seem to pick up anything new today.
Then I read your thread and (cunifer ) my new thing for the day.
Can't say I have heard of this product.
Here in Australia we use Bundy tube But it's not easy to bend.
Luck for me these brake tubes were in good condition and I could reuse.
Please explain more about this product.
Photos as always are excellent .
Reason I asked about the spacer is when the two mounts are together is the spacer the correct length.
Still manning the china office. Another 5 days to go.
I want to start on the body when I return. We can compare welds.
Wire loom if you need spade pins or connectors I have sourced these in china.
Keep up the good work.
Cheers



...via IH8MUD app

 

[micdon]

Hi micdon
My mother once told me its a sad day when you don't learn something .
Well I was a bit worried because I did not seem to pick up anything new today.
Then I read your thread and (cunifer ) my new thing for the day.
Can't say I have heard of this product.
Here in Australia we use Bundy tube But it's not easy to bend.
Luck for me these brake tubes were in good condition and I could reuse.
Please explain more about this product.
Photos as always are excellent .
Reason I asked about the spacer is when the two mounts are together is the spacer the correct length.
Still manning the china office. Another 5 days to go.
I want to start on the body when I return. We can compare welds.
Wire loom if you need spade pins or connectors I have sourced these in china.
Keep up the good work.
Cheers



...via IH8MUD app

Here's all I know about cunifer:

It's name comes from the alloy Cu Ni Fe. It's 89% copper, 10 nickel and 1% iron. It's way easier to bend then steel, but a little harder then normal copper. I think you can get away with using one of the cheaper flare tools, but because I planned doing all of them i bought a proper tool so I don't know for sure. It doesn't work harden and is corrosion resistant. It was developed by volvo somewhere in the 70's (but that's for history buffs)

I found some in Australia via myshopping.com.au

Good luck in china and thanks for the connector offer but I'm still stocked up

 

[micdon]

Because the front fenders are in too poor a condition to reinstall, I bought some 2nd hand ones. So I had to remove the aprons and guess what I found??
Holes and rust aplenty.

Here's my first attempt at actual bodywork.

Repair patch welded in

And ground flat(ish) I'm sure with a skim of bondo it'll be fine

Here is the first one after the 3rd coat of brunox rustconverter/primer

Dang. looking at this pics my garage is a real mess and kinda empty since 90% of my tooling is moved to where the truck is... Do I wish I had 2 of everything

 

[Bambi Girl]

Hi micdon
Cunifer thank you for that . I will try and track some down.
You are powering along with your project.
Very inspiring are your photos.
Please post some photos of the chassis when finished.
So much I could be doing on my build looking at your photos and getting inspired but still stuck in China.
Count down 3 days.
Keep the photos coming .
Cheers



...via IH8MUD app

 

[micdon]

First of.. Bambi, how was china?

Soooo..... it's been a week now. And a fruitful week it has been.

Here's 75% of the chassis

And here's the rest.. Anybody likes puzzles??

Chassis going back together. The rear end of the chassis is bolted back together using grade 10.9 M10 domed head bolts with a allen key , The axles are scheduled for OH at the end of the summer

 

[micdon]

Next up was the reinstall of the motor, but not before it got a nice wash. The nextdoor neighbour came by with an excellent plan to simplify cleaning up after washing the motor. DO IT OUTSIDE!!!! Ow yess, the tractor is a 25HP porsche diesel build somewhere in the 1930's/40's and is still in active duty
John

Motor cleaned and reinstalled. Motor rebuild is scheduled for when it breaks down(which should be NEVER)
http://imageshack.com/a/img838/2581/***5.jpg

 

[micdon]

After the motor reinstall, time to get the body on. And here I ran into some issues. First, the front driveshaft was stuck. I couldn't get it to extend or retract at all. Only after some serious hard handeling would the 2 halves comes apart. Then when I tried to reinstall is back into the truck, the driveshaft was too long. So I removed the grease zerk, applied pressure and here's what happend

I figure that the reason I couldn't get the drive shaft apart was a vacuum in the shaft. And the reasons it wouldn't shorten was too much grease. Am I right in assuming that the driveshafts should only be greased sparingly??

Also ran into another issue with the dynastar bodykit... How on earth do those guys figure you can install the "hockey-pucks" over the rear axle, when there's only a straight hole down the middle? So here's what I did. With a step drill, I drilled a tapered hole in the mount.

Then placed a washer in the hole

And installed on the truck using the standard toyota screws. I'm hoping those beams can last another year.....

 

[micdon]

Last is a picture of how I left the sponge this afternoon

Next week I've got another few days. Hope to get it running by then

 

[Bambi Girl]

Hi micdon
Back from China . Thank god home to good food and no pollution.
Well what can I say about your last photos.
Do you Sleep?
That is a truck load of work in one week.
You have powdered ahead on me.
Excellent work .
Hay what am I going to do for my micdon fix now you are finished.
Looks real good and you are a week off driving . Jealous .
I like the photo of the motor and tractor.
A photo of a view from my china house balcony .
A photo of my build so far
Cheers

...via IH8MUD app

 

[micdon]

@Bambi Girl : dont worry, it's take a be a while yet. Damn, china looks busy. The reason its coming along in a steady pace is because I pick my battles and leave what's not on the todo list for another time. I would love to have the time and space to do a complete rebuild in 1 go like you are doing. How far along are you on the body? My front clip is going to be a battle I believe but we will see. The hood is new, the aprons patched and almost repainted, the fenders are second hand and I'm still lokking for a new front...

 

[Bambi Girl]

Hi micdon
I have been home for a week and only had one day to play Toyota.
I have a new project from China on the go and it's keeping me busy on the Lathe and Mill making a prototype.
I hope to have this finished next week and back to it.
On the 40 body I have completed the roof . Big job as I had rust in the gutter.
The rear doors are finished as along with the top rear side panels.
I have all the rubbers . That took some finding.
The tub is rust free and the original Toyota undercoat is to be found on the inside of the panels.
I will buy a car rotisserie to put the tub on over the next few weeks.
Will post a photo for you.
Did your body mounts work out ok in the end?
I can not understand why you had all the problems with kit that was supposed to fit.
Have you any further ideas why the mis fit?
I looked with great interest at your solutions.
As always keep the photos coming. And keep up the good work.
Cheers



...via IH8MUD app

 

[Bambi Girl]

Hi micdon
Got my body to test fit the chassis today.
I looked at the front body mounts with great detail.
Yes they are the same as yours. A mis fit of 5 mm.
Why ?
I will look into this in depth and report back.
Cheers



...via IH8MUD app

 

[micdon]

How did you repair the gutter? Did you use a repair kit, install a complete new gutter or did you you fab yourself? As all raingutters i've seen here in holland, mine has got SERIOUS issues. But new is impossible to get and aftermarket is too expensive to ship. So i was wondering what you did.

Weird huh on those bodymounts. Stil have to contact daystar about it. I got a request to rate their kit and the fitment..... Can you quess my awnser? Check the mount on the rear bumper as well. I think you'll find the same issue.
Ow, and just as a heads-up... If your fueltank is under the cab as mine is, you might want to think about when you put the RH middle bodymount bolt through the hole in the body. It is possible when the body is on the chassis and the tank is installed but believe me, it's a

Why are you buying a rotisserie? I thought about welding one myself to save a penny

 

[micdon]

here's one for the purists:

I know somebody posted a list with all miscellaneous parts, but I can't find the thread anymore.
Anyhow, there are several different lengths off cable clamps. Sadly the length is not noted on the Toyota list. This is the shortest one...

 

[Bambi Girl]

Hi Micdon
Re your clip.
I have seen them advertised but did not take note of were to find when needed.
Now I have started on the body I will need an array of body clips.
If I find before you I will post the location.

Yes I agree with the middle fuel tank body mount. Tricky to put the bolt in. This mount, the top fits but the bottom mount does not look like a match.
The fitting instructions show no gap between the top mount the chassis and bottom mount. Impossible with the parts supplied.
The metal crush tubes are to short. I must be doing something wrong.
Still more research to be done here.

The roof
What a job. Very happy with the results but a lot of work.
The rust was isolated to four areas with the rest of the metal gutter not being to bad. The fix was helped with a purchase of a small metal bender. (eBay $165.00 new German ).
Cutting out the affected parts then re fabricating with the aid of the bender I was able to get a near perfect patch.
My sheet metal welding skills are not to bad.
I made up new aluminum rivets re sealed and painted.
Would I do this repair again? May be not as cool cruiser s claim to have the roof gutter available in piece from.
$350.00 sounds cheap to the amount of time I put into the job.

The rotisserie I did the sums $800.00 new delivered eBay .
Use it for a month then re sell. If I got $600.00 back I would be happy
I do not want to grit blast the tub so the rotisserie will be a good tool for me to get the tub prepared and ready for paint.
Plus I can rotate the tub at will when working alone. All this for $200.00 bargain.
A photo of the body mount fitting sheet.
Feel free to comment.

Looking forward to your next photos.
Cheers

...via IH8MUD app

 

[micdon]

HA, found the list...

Butttttt, mine is not on the list????

You're right about the middle bodymount. I guess I already repressed it

Did your raingutter look something like this ? Pretty much all the inside looks like this, the outside is okay. I wonder what happend? Maybe condensation due to missing door rubbers on my amby doors??

Anyway, waiting on my fenders and aprons to dry. Finally done painting

colour was as a rattlecan job. After that clearcoated with 2K. Fisrt time using a proper paintgun. Pretty happy with the result, but it takes some adjusting and getting used to. DUST IS THE ENEMY. Glad to have listen to my neighbour, to shoot a thick layer. Now at least I can polish out most of it

Finally general pic of my partsroom. Can you guess what's in the large box

 

[Bambi Girl]

Hi micdon
Thank you for posting that clip parts list.
Wonder how many of them are still available From Toyota?
Your roof gutter!!!???
Think you need a new one there.
What surprises will you find in the side panels under the roof gutter?
If your sheet metal working skills are as good as your welding and fabricating skills you should have no trouble making a new one.
Have you checked out the cool cruiser web site ? You may get some ideas if you check out there roof gutter assembly.
If you decide to make your self i can throw in some ideas if you get stuck.
Pity you are so far away as I would come and lend a hand.
Got me guessing . What's in the box in the parts Room.?
Today I have to master the spraying of a 2 PAC primer.
Will take a photo when finished so you can comment.
Keep up the good work and keep the photos coming.
I real enjoy following your build.
Cheers .


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[micdon]

Thanks for the tip of checking CCOT. I had a look at their gutter. I think I'll be able to fab it as long as I can reuse the old corners. Did you buy one of those benders you place in the workbench vice? I always wondered about them. They look like a real asset to the shop.
Don't really want to think about the hardtop sides (same as the windshield frame btw) it scares me already.


How are you going on the bodymounting? I never thought about a selling on tooling I no longer had a use for. It is a great way to save some money.
I guess secretly I'm a tool-hoarder

How did the painting the primer go? It helps when all the parts are a bit warm. Especially when you start laying down colour. A nice tip I got is to always spray a (very) dry coat first. This will help the "wet" layer to stick way better. Shoot wet layer 5 min after dry. Don't use a too coarse sandpaper when sanding down any layer before you shoot color. Especially when you go for a darker color. You WILL see sandmarks through the paint (ask how I know) If you're happy with the surface finish, you can even use 400 or even 800 grit wet. And (but this is personal preference) sand the last layer of primer in 1 direction only. So that even if you do see sandmarks trough the paint is will always only be from 1 spot. Normally when getting a panel flat, I sand in 8 directions. Last tip and then I;ll stop pretending I know about painting cars: Shoot the "wet"layer of paint as wet as you dare. If you get it spot on there will be NO orange peel. But the window between orange peel and running paint is very small.

The contents of the box is my special pride. It's the last available OEM hood in the country. Even the Toyota dealership can't get another one

 

[Bambi Girl]

Hi micdon
First your roof gutter.
Yes the 300 mm vice mounted finger folder is one great asset. It's good for up to 1.5 mm. I have a lot of fun playing with this one.
I see you are concerned about the roof corners. Why ? With your skills you can make the corners.
If you decide to go this way I can guild you through the lip bending process. You will need to make your self some simple tools to do the job.
I fitted a second fuel filler ( 1980 style ) this required neat folding.
Not the best photo I have got but the only one on this iPad .

The body mounts I have done no more detective work on this problem. But it's coming.

How did you get a new Hood? Well done.

Now thank you for all the painting advice. I have read and read your words.
Nicely written.
Conclusion
Your skills here are greater than mine.
If it's mechanical i can fix. If it's steel I can weld. If it's broke I can make on the lathe.
Painting . Tac times, wet coat , dry coat, spray in one direction . It's all in your detailed instructions .
If I stuff up I have to start again . Big job.
So two options here.
1 You come to Australia to paint for me.
2 I send it to a paint shop for the color coat
In saying that I was happy with the 2 PAC etch primer I sprayed on Sunday .
While I was painting Nat my partner started on the tub.
Very happy with her results.

 

[Brad 1979 HJ45]

hi guys, both your builds are looking great. Keep up the good work