Builds Sandy the Tan FJ60 (2 Viewers)

[GLTHFJ60]

I can't think of another example (on the forum anyway) where someone has taken the roof cap off to repair the upper body structure like this. I'm super stoked that @Hokie LX chose this path.

One neat thing I learned today is that the entire rain gutter is spot welded to the body stampings from the outside, then the roof skin is spot welded only to the rain gutter on the sides and rear. So easy to take apart!

These bodies all rot from the inside out in the top half, and looking in like this really shows where to cavity coat to slow the rust down. Gotta spray the whole length of the structure from the access holes, but also (and probably more importantly) above the structure against the skin as it comes down to the rain gutter.

 

[cruisermatt]

my replacement body shell is 99% rust free (visually) but has a tiny spot on the roof now I am definitely considering doing all this to it before paint.

 

[GLTHFJ60]

my replacement body shell is 99% rust free (visually) but has a tiny spot on the roof now I am definitely considering doing all this to it before paint.

Stick a borescope in to have a look before you do.

 

[open country]

Following as well, nice work fellas.

 

[Hokie LX]

Had another work day yesterday on the 60 roof. We welded in the patch panels on both sides and reattached the gutters on the passenger side.

Next work day will be reattaching gutters on the driver side and then starting on the roof cap and maybe even getting the roof cap set back on the truck! As always, this program is brought to you by @GLTHFJ60 who's generous support makes this project possible.

Passenger side patch and gutter reattached and primed

 

[Hokie LX]

Driver side rear corner dropped in damn near perfectly. Can't even tell it was patched.

And finally the patch above the driver rear door.

 

[garfieldthecat]

Had another work day yesterday on the 60 roof. We welded in the patch panels on both sides and reattached the gutters on the passenger side.

Next work day will be reattaching gutters on the driver side and then starting on the roof cap and maybe even getting the roof cap set back on the truck! As always, this program is brought to you by @GLTHFJ60 who's generous support makes this project possible.

Passenger side patch and gutter reattached and primed

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That gutter went on there seamlessly. Was it TIG welded on the outer-facing side? As you know, there is a fold on the outer facing side that loops back in to the inner gutter. Was there anything special needed to get the folded over outer lip of the gutter to weld up on both the outside of the gutter as well as the inside? Great work and thank you for all the photos, it really helps with visualizing the process.

 

[GLTHFJ60]

That gutter went on there seamlessly. Was it TIG welded on the outer-facing side? As you know, there is a fold on the outer facing side that loops back in to the inner gutter. Was there anything special needed to get the folded over outer lip of the gutter to weld up on both the outside of the gutter as well as the inside? Great work and thank you for all the photos, it really helps with visualizing the process.

Nope, mig welded and careful sanding the weld down flush. Nothing special for the fold in the gutter either, that just gets welded solid and reshaped too.

 

[garfieldthecat]

Very cool and inspiring. Great welding skills too.

 

[GLTHFJ60]

Very cool and inspiring. Great welding skills too.

Lol, repeat after me; "a grinder and paint makes me the welder I ain't"

Seriously though, lots of prep and some prior experience to get it to finish out like this. The goal is always to make it look like no repair was ever done.

 

[4runner2FJ60]

Are you using .023 wire?

 

[GLTHFJ60]

Are you using .023 wire?

Yes

 

[Hokie LX]

Had a productive evening with @GLTHFJ60 today.

We got the gutters welded back on on the driver side and look amazing.

 

[Hokie LX]

Then we started on the roof skin. You can see the skin that came off here. Really bad sections on the back edge and above the passenger door especially.

And the donor skin which was "rust free". I took a picture of the outside parts we cut out to show how it looked outside and also an inside picture showing how bad it was inside.

Then here are the sections cut out of the donor roof that are being patched. We are taking metal from the factory roof to patch with. I also stripped out the factory insulation as the entire skin will get insulated once reinstalled.

 

[Dekeman]

Massive job. Amazing work.

 

[Hokie LX]

Got some nice comparison pictures of the new vs. old patches of metal. Obviously not prepped or trimmed yet.

The rusty parts are what came out of the "rust free donor roof".

 

[CenTXFJ60]

Dam!!! That’s all I can think of. Incredible. I have several 60’s in this state and stoked to get these free lessons on how to do it

 

[garfieldthecat]

Had a productive evening with @GLTHFJ60 today.

We got the gutters welded back on on the driver side and look amazing.
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Which sealer will you be using under the rain gutters? I imagine it needs to be one that sticks in place and won't run down the sides.

 

[Hokie LX]

Which sealer will you be using under the rain gutters? I imagine it needs to be one that sticks in place and won't run down the sides.

Planning to use 3M heavy bodied seam sealer 08308

 

[Hokie LX]

Had another productive day with @GLTHFJ60 working on the 60 roof. Put the roof cap on to weld in the patch panels to attempt to keep the roof skin somewhat in shape. They all welded in fine after some trimming. The patch panel on the passenger rear of the roof (pic 2) is on a contour curve put the patch we cut slotted in nicely.