Build Salted Pork fj55 family wagon build

[Roastchestnuts]

Well I did some more welding today. I just see rust and I cant stand it!

Today I tackled some of the typical hood rust. It will just get worse if I don't fix it. I can see why this happens. once water or something gets in there it gets trapped. I think the plan after i get all done is to get fluid film or cavity wax or something to spray in this area and just periodically apply it to keep it from getting worse. I did clean the scale off and spray it with some rust converting paint before I welded it up. Not that it will do a whole lot but its a good piece of mind. Dont worry I did paint strip the area before I welded the patches in.

Both passenger side and driverside corner pieces below I cut out too. I found lots of mud and rust packed behind here that I cleaned up .

It still needs lots more work but I have the patches welded in. I need to grind down the welds and then get everything painted and looking good again. But at least its not some rust holes just letting more moisture in there rotting things out.

 

[Roastchestnuts]

I worked on the hood some more yesterday. Yesterday got up to 60 degrees! I ground down the welds and did a little skim filler to level it all out. Thankfully it did not take too much and I didnt warp any too bad welding up the holes. it looks really good. I was running outof daylight so Just have a weld through primer to protect it. Ill shoot some high build primer on it to completely protect it on the next warmer day.

 

[Roastchestnuts]

I started digging into the passenger rocker yesterday. I cant believe how much large scale rust flakes were inside the rocker! I bet this held so much moisture when I drove it in the rain. Makes me happy I started on the passenger side too. Luckily this side the floor pans look way better. The front body mount area is the only issue. where on the drivers side I had to make patches pretty much from the front floor pan to the rear seats.

Look at this awesome bondo repair job..... a good example of how not to repair rust.

so much bondo was used.

The little fender flair I think I am going to cut off. its got a lot of bondo in it too. I think I am going to have to remake it like I did on the drivers side.

This is pretty much where I stopped. I learned from the drivers side and made alot of measurements. I am planning on marking the positions of the doors and door hinges to avoid so much adjustment before i remove the doors. I also wrote down the measurements from the rain gutter to the top of the rocker in 3 spots. I think it was all about 4 feet but I have it written down. Plan is to brace up every thing, get the rest of the old rocker out, cut out the front body mount and pan then start fitting the new rocker. Ill have to replace the rear body mount his time maybe too. The upper part of it is fine but where it attaches to the rocker is rough. I have a replacment at least. also the floor supports on this side are good to go. they wont need replacing.

 

[Roastchestnuts]

also for your viewing pleasure here is the newest Chestnut in the samurai yesterday!

 

[Roastchestnuts]

Well one of my goals was to get this passenger side cut out and welded in before I go back to work from my paternity leave. looks Like I have gotten almost to that goal. I supported the A and C pillars while I cut everything out. the A piller on the drivers side was way worse than the passenger side. Not nearly as much rust repair on the passenger side a pillar. Then again I found alot of mouse house on the drivers side rocker and a pillar.

The body mount here was much more difficult on the passenger side to cut out. No room, gas line and brake line kinda in the way, and it was way less crumbly haha. Still it came out in 3 pieces. had to bust out the air hammer because it was the only thing that I could get to fit in the area where the body mount was spot welded in a few spots.

I got the rocker tacked in and measured out within a 1/16 of an inch from where stock was. Of course I had to stop here because it started raining. I have not welded the b pillar yet. I want to bolt the front door back in temporary to make sure its all lined up. I forgot to measure out the b-pillar... I Think It will be Ok. I will at the very least just do a couple of tacks then readjust as needed. But I am happy with how this is coming together. about 70% of the way there.

does anybody know where I can get this weather stripping with the welting???? I bought this one from SOR for the drivers side but they want 50$ for each door and 30$ shipping.

Side note - I bought another camera... this one is really really cool guys. vintage 2004 make. but it was the first digital rangfinder. wopping 6mp. and weirdest part EPSON made it. Its a Epson RD-1. But you wont believe how beautiful the images I am getting from it. also this camera works like a film camera. you need to operate the film advance lever to take a photo. it actually cocks the shutter. @RevISK this is a cool one!

Best part is I got a good deal and its in fantastic condition for a 22 year old digital camera.

Shot this most rusty isuzu trooper with the epson Rd-1. Finally a car rustier than my stuff.

It makes beautiful black and whites too!

 

[svsisu]

does anybody know where I can get this weather stripping with the welting???? I bought this one from SOR for the drivers side but they want 50$ for each door and 30$ shipping.

Amazon has lots of edge trim and edge trim bulb seal listed. Might find what you are after there with some measurements, prices vary greatly for no real reason. Hopefully the link works and you find something.

Amazon.com : edge trim bulb seal

Nice work on all the rust remediation!

 

[charliemeyer007]

Large Bulb Trim Door Rubber Seal, 0.70" Bulb Diameter, 0.90" Height –

Tight Seal with Large Bulb: Features a 0.70" (18mm) bulb diameter and 0.90" (23mm) height for excellent compression, ensuring a firm seal between door and body. Universal Grip Range: Accommodates metal edge thickness from 0.039" to 0.23" (1–4mm), fitting most vehicle and equipment doors...

mmseals.com

 

[RevISK]

Well one of my goals was to get this passenger side cut out and welded in before I go back to work from my paternity leave. looks Like I have gotten almost to that goal. I supported the A and C pillars while I cut everything out. the A piller on the drivers side was way worse than the passenger side. Not nearly as much rust repair on the passenger side a pillar. Then again I found alot of mouse house on the drivers side rocker and a pillar.


View attachment 4086765

The body mount here was much more difficult on the passenger side to cut out. No room, gas line and brake line kinda in the way, and it was way less crumbly haha. Still it came out in 3 pieces. had to bust out the air hammer because it was the only thing that I could get to fit in the area where the body mount was spot welded in a few spots.
View attachment 4086766

I got the rocker tacked in and measured out within a 1/16 of an inch from where stock was. Of course I had to stop here because it started raining. I have not welded the b pillar yet. I want to bolt the front door back in temporary to make sure its all lined up. I forgot to measure out the b-pillar... I Think It will be Ok. I will at the very least just do a couple of tacks then readjust as needed. But I am happy with how this is coming together. about 70% of the way there.
View attachment 4086767

does anybody know where I can get this weather stripping with the welting???? I bought this one from SOR for the drivers side but they want 50$ for each door and 30$ shipping.
View attachment 4086768


Side note - I bought another camera... this one is really really cool guys. vintage 2004 make. but it was the first digital rangfinder. wopping 6mp. and weirdest part EPSON made it. Its a Epson RD-1. But you wont believe how beautiful the images I am getting from it. also this camera works like a film camera. you need to operate the film advance lever to take a photo. it actually cocks the shutter. @RevISK this is a cool one!

Best part is I got a good deal and its in fantastic condition for a 22 year old digital camera.
View attachment 4086774
Shot this most rusty isuzu trooper with the epson Rd-1. Finally a car rustier than my stuff.
View attachment 4086780View attachment 4086781
It makes beautiful black and whites too!
View attachment 4086797

I actually remember this camera.
That is rad!

 

[Roastchestnuts]

I got some photos back from the lab! I have been shooting alot less film than I did a few years ago.It just got soo Expensive. Cost me 85$ for developing 5 rolls of film. 3 rolls of medium format and 2 rolls of 35mm. I would do it myself but I have a newborn now and those chemicals are very toxic. But you cant argue with the vibe you get from a film photo. These were taken with 3 different cameras. My 1961 rolleiflex 3.5f with kodak gold 200 is the first photo, the second photo was taken with my Nikon s3 and 50mm f1.4 and kodak gold 200, and the last 3 were taken with my ricoh gr1s and harman Phoenix 200 II film. Makes me want to get cranking harder on this project. I can see the light at the end of the tunnel at least.

 

[Roastchestnuts]

I actually remember this camera.
That is rad!

I do too. It came out right when I was getting into photography. I really wish i had gotten this camera years ago too. its really good. better than you would think. I am shooting it with a pretty soft 3.5cm nikkor lens and am getting good results! Missed focus below but it really shows that grain you get at 1600 with 0 banding. it looks like film to me actually. the only thing that is missing is the weird artifacts you get from dust haha.

 

[Roastchestnuts]

also check out this cool jeep ambulance I shot in the snow.

 

[Roastchestnuts]

Amazon has lots of edge trim and edge trim bulb seal listed. Might find what you are after there with some measurements, prices vary greatly for no real reason. Hopefully the link works and you find something.

Amazon.com : edge trim bulb seal

Nice work on all the rust remediation!

Thanks!! these fj55s do seem to rust from the inside out. Like it wont show on the outside until its all the way through. I think I have mitigated most of it. Luckly I think the upper from really the rockers up everything seems to be rust free. Except for that spot on the hood that I fixed. I am kinda dreading it but I do need to get the windshield gasket and windshield replaced eventually. I wonder If I will be able to get that done In eastern NC.

and thanks for the tip! I just need to measure it out I guess.

Large Bulb Trim Door Rubber Seal, 0.70" Bulb Diameter, 0.90" Height –

Tight Seal with Large Bulb: Features a 0.70" (18mm) bulb diameter and 0.90" (23mm) height for excellent compression, ensuring a firm seal between door and body. Universal Grip Range: Accommodates metal edge thickness from 0.039" to 0.23" (1–4mm), fitting most vehicle and equipment doors...

mmseals.com

thanks!!

 

[Roastchestnuts]

Last update for today. I need to grind down alot of welds today. If you squint its fine. Obviously It needs alot more work but she is sturdy! I also like I said before thought I would have to make this corner piece and I did. Made this from left over panels from my Suzuki samurai project. I copied the template I made for the drivers side and created this patch. Needs another couple small pieces welded in but it works. reduce reuse. seems to be the same gage as the fj55. I think it was 20 gage. I still need some more work but I feel confident that It will turn out like the drivers side did.

 

[onemanarmy]

Oh baby! those M715 amberlamps are quite rare!

Thanks for the updates and sweet pics!

 

[Roastchestnuts]

Oh baby! those M715 amberlamps are quite rare!

Thanks for the updates and sweet pics!

Thanks!

Its pretty cool. the guy that owns it here has a couple of other really cool military 4x4s. He is the guy that was going to help me with the split rims. I also have always wanted one of the m715 convertable trucks. they seem pretty badass plus along with my favorite things it has a fold down front windshield.

 

[RevISK]

I do too. It came out right when I was getting into photography. I really wish i had gotten this camera years ago too. its really good. better than you would think. I am shooting it with a pretty soft 3.5cm nikkor lens and am getting good results! Missed focus below but it really shows that grain you get at 1600 with 0 banding. it looks like film to me actually. the only thing that is missing is the weird artifacts you get from dust haha.


View attachment 4087952

That really does have a film grain structure.

 

[Roastchestnuts]

Front passenger floor pan and body mount burned in! the toughest parts were the left front corner. the new pan was more angular here where factory was more smooth curves. nothing a body hammer and some gentil massaging could not handle. That cat eye shape close to the trans hump was a rust hole that I cut out. It just ended up being a goofy shape. I need to put the bolt through the body mount and patch the holes that were hiding under the seat mount. I am planning on installing the seat and then tacking the seatmount back in. then remove the seat and weld the mount in. I just want to make sure everything lines up eventhough I have measured everything. Next is sanding and priming with some high build primer. I think I am going to leave the welds on the pans since the rubber mat will cover most of this.

This fj55 has got to be super ridged now being the rockers are 1/8 inch thick metal. and the fact that the front body mounts were not connected at all anymore. . I am planning on buying some cavity wax for the rockers I feel like that would be good.

Random question - what self leveling seam sealer would you guys use for the rain gutters?

 

[brian]

I can't see filling the rockers with anything other than sailboat fuel being a good idea.

 

[svsisu]

I can't see filling the rockers with anything other than sailboat fuel being a good idea.

Sailboat fuel? Wind?

 

[Roastchestnuts]

I can't see filling the rockers with anything other than sailboat fuel being a good idea.

Our sailboat had a huge diesel tank and a tiny little perkins diesel motor in addition to the sails.

Sailboat fuel? Wind?

haha.

Yeah I am going to use cavity wax. @svsisu you know how bad every thing rust down here if left untreated. it will be a rust concretion before you know it if left to its own.