Ruby: Body work /resto-mod

[Old Nick]

Howdy, all,

Mechanically, I've got my '62 sorted out (in large part due to the vendors on this site!). My interior is also completely refreshed... new carpet from this forum, new door cards, etc.. Today, I'm getting started on my long overdue body work, again, with so much help from the wisdom shared here.

Just removed all of the chrome from the front end, and started on removing the DS fender (already ran into one stripped bolt... ugh). Other than that, it's coming along fine. But, a little worried about what I'll find once I start taking her a part.

I've got rust in all of the usual places (fenders near DS and PS door, rockers are toast, rear wheel arches, and both rear quarters) and Wolf Steel patch panels to weld in. It had been my plan, for the better part of year, to have someone else do the welding, but I've got so much sunk into my truck, that I thought eff it. I'll learn how to weld. My neighbor has kindly offered to let me use his welder and to come over to guide me through it, in exchange for some beers.

As things progress, I'll post up some pics... and surely questions will arise when I hit a wall from time to time. Thank you in advance for your advice and help.

More to follow.

 

[dbleon]

Good luck and post pics! I’m a pretty crappy welder .. but sheet metal is especially challenging and tedious to get right.

 

[Old Nick]

Good luck and post pics! I’m a pretty crappy welder .. but sheet metal is especially challenging and tedious to get right.

Thank you! Got a bunch done today.

The PO (there was only one as far as I can tell) skim coated the entire inside of the wheel well with what appears to be seam sealer (and that was covered with an undercoat). I haven't been into it until today, so I was surprised. Never seen anything like it. Getting the bolts out was a serious PIAT. But they are out!

Tomorrow, the hood and then the DS fender come off. Hopefully, I'll get the PS side off too. Lots of fun... bagging and tagging everything.

I'll post up pics this weekend.

 

[Old Nick]

Got my front end disassembled, hood off and DS fender removed.

 

[Old Nick]

Not sure why it’s coming up sideways...

Anyway, here is a side view and some detailed pics highlighting the hidden rust:

 

[Old Nick]

My first time removing the fender from a ‘62. Took me far too long. That said, I’m constantly amazed at how wonderfully these trucks are engineered.

the worst part of the fender removal was that I had to flap wheel then razor blade the seal between the well and the fender... total bummer.

the PO did in fact build up and skim coat (with seam sealer) the seam between the fender and the well, and packed in fiberglass and bondo in the lowest portion of the fender... by the DS door. The front portion of my rocker (under the fender) was pristine. Couldn’t believe it!

Tomorrow, I’m going to tackle the PS side fender and see what’s waiting.

I’ll post up some more pics soon.

Then it’s doors off, windows out, welding and then prep for paint.

set a goal of one month (laughing), to get my truck back on the road!

friends, if you see me making a mistake, please chime in.

take it easy.

 

[Old Nick]

Good luck and post pics! I’m a pretty crappy welder .. but sheet metal is especially challenging and tedious to get right.

Thank you! Yeah, I’m a little nervous re: the welding, but I’ve been watching tons of how-to vids... building up my confidence.

 

[Old Nick]

If any fellow '62 owners happen to read this, have any of you deleted your manifold cooling fan? Mine has kicked on all of one time since I bought my truck some years ago and it gets plenty hot here in the summer.

Don't have any issues with hot starting.

The reason that I ask is that this fan is also, I think, the carb cooling fan on the 60 series. Does an 3FE/EFI really need this fan?

 

[Old Nick]

Got the PS fender removed today. Went much smoother than the first. Uncovered some rust, but it's fixable.

First pic. is the front PS corner where the worst rust is located.

Second is a side view.

The third compares the Wolf Steel patch panel with the OEM body line of the fender. There is some forming to do, for sure, to make it fit properly, but on the whole, the panel look pretty darn good.

 

[Old Nick]

My front bumper was apparently bent and straightened previously. One of the large bolts on the underside, PS, is ever so slightly bent and won't budge. Going to try heat and a mallet. Fingers crossed I can get it to break.

More to follow.

 

[Old Nick]

Got my PS fender down to bare metal. Sanded off the surface rust and treated the entire fender with a KBS phosphoric acid compound. Did the trick beautifully. Got two coats of KBS on the outside of the fender (brushed on). Tomorrow, I'll do the interior. This is probably overkill and or stupid, but heck, I'm going to be Monstalining my truck 2-tone. Just got a delivery from Magnet Paints today.

Please don't warn about the dangers of lining my truck, trapped rust, etc. I know the risks and I'm doing everything I can to handle rust. This truck, God willing, is never going to be sold, so I'll do with it what I please and enjoy the heck out of it.

I'll post up some pics tomorrow.

Take it easy.

 

[Old Nick]

Got my first fender (only exterior side thus far) coated with KSB and started sanding in preparation for the Monstaliner.
The coats of KSB that I applied were too thick (see some of the bumps in the pic). Won’t do that on the next fender, etc.
Now, I just need it to quit raining so that I can start cutting and welding.

Edit: I used KBS coating, not KSB as stated above.

 

[SteveH]

If any fellow '62 owners happen to read this, have any of you deleted your manifold cooling fan? Mine has kicked on all of one time since I bought my truck some years ago and it gets plenty hot here in the summer.

We have to assume they didn't just include it for grins. Mine came on once when four-wheeling and once another time, but nothing like the fan in my FJ40. I left mine in place - I have to assume it was a conscious decision by Toyota. If you want to save weight on an FJ62, ditch that silly air pump bypass silencer - it does virtually no good and is a big honkin' 'thing' you can get out of there. Also, delete the 'dead pedal' in the driver's footwell, and enjoy stretching out your left leg. Cover the hole in the floor with a floor mat.

 

[Old Nick]

If any fellow '62 owners happen to read this, have any of you deleted your manifold cooling fan? Mine has kicked on all of one time since I bought my truck some years ago and it gets plenty hot here in the summer.

We have to assume they didn't just include it for grins. Mine came on once when four-wheeling and once another time, but nothing like the fan in my FJ40. I left mine in place - I have to assume it was a conscious decision by Toyota. If you want to save weight on an FJ62, ditch that silly air pump bypass silencer - it does virtually no good and is a big honkin' 'thing' you can get out of there. Also, delete the 'dead pedal' in the driver's footwell, and enjoy stretching out your left leg. Cover the hole in the floor with a floor mat.

Howdy, Steve,

I've pulled all that stuff out of my engine bay , and I should pull the "dead pedal". My door has a nice little impression where my knee rests. I know that Toyota includes things for a reason, but while my truck is apart, I thought I might as well ask to see if anyone has pulled the fan, and if their truck continued to run ok. It doesn't hurt to ask (laughing).

Thank you for responding.

Take it easy.

Edit: BTW - I dig your signature line.

 

[SteveH]

Oh, I think the 3F-E can easily handle the underhood temps.

I do open my hood after parking on long, hot days to let the staggering heat load out of the engine bay. But, as someone who has suffered with hot soak (carbs heating after stopping) on FJ40s and 60s, I would be loathe to remove anything that might keep the fuel system cooler.

 

[Old Nick]

Oh, I think the 3F-E can easily handle the underhood temps.

I do open my hood after parking on long, hot days to let the staggering heat load out of the engine bay. But, as someone who has suffered with hot soak (carbs heating after stopping) on FJ40s and 60s, I would be loathe to remove anything that might keep the fuel system cooler.

I’m not carbed, but your post has made me think about Toyota’s engineering. I’m not going to delete the fan just yet.

thank you for chiming in.

 

[Old Nick]

Got my hood down to bare metal today. Just the start of this project has given me a sincere appreciation for the craftsmen/artists who do this full time. Dang it’s a lot of work!

here is my hood (had to sand inside of a portable tent room... the vibrations from my grinder sent the bloody cicadas into an orgy):

 

[Ian Crawford]

Good progress!!

 

[Old Nick]

Good progress!!

Thanks, man! It’s coming along slowly but surely. Humidity and flash rust are a total pain. Phosphoric acid has been a lifesaver.

 

[Old Nick]

Monstaliner on my hood. Desert sand/dirt bag. Turning out pretty well.