Sill Cover Replacement - 1977 FJ40

Joined
Jan 24, 2020
Messages
17
Location
Portland, Oregon
So to start, I’m new to sheet metal work but have done small part fab before. Trying to tackle some of this on my own.

As far as I can tell, the sill cross member behind the round side of the quarter panel has little to no rust. After tearing off the sill cover, I found rust on the top of the cross member in a few areas, but the metal appears to be repairable.

So my question: can I patch/integrate sheet metal into the existing cross member, and then install the sill cover? Or do I need to do a full replacement of the cross member. Now, if you look inside the cross member, it’s rust free. I can even see the original color of the steel coating. And the steel behind the quarter panel is free of corrosion.

I’d be curious to know thoughts/advice on this.

This rig is not a restoration. I enjoy driving them on trails with light off-roading. I’m including the before and after removal of sill cover pics.

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Joined
Apr 21, 2005
Messages
21,831
The main sill is structural. I wouldn’t be patching it. Beside the tub hard top is putting a lot of downward force on the sides of the sill. It thebone continuous piece that support the ends. Not sure about the ambulance door model with the notch but my 73 FST the top and half way down the back are three layers. The main sill, the back floor then rear cover. On my 73 FST this is the worse rust.
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The sill is still intact. Because it will not have to support a hard top will just patch the quarter panel. May look at some extra support inside the sill because the spare tire is support on this side. Other side would not be a concern.
 
Joined
Jan 24, 2020
Messages
17
Location
Portland, Oregon
My '77 40 seems to have rusted first on the sill piece. I believe it was left in the rain and just sat like that for two decades. The PO did not drive this vehicle for about 25 years. For this reason, there's little to zero corrosion underneath the vehicle. There's also no corrosion on the curved parts of the sill support behind the rear quarter panels, just the top of the sill. Looking at other rigs that seems to have corroded from water/debris getting caught during driving, I can see how that area would corrode. However, mine is different.

Given these circumstances, would a patch in the areas where it rusted suffice? Again, there is zero corrosion where the cross member extends to the curved part of the quarter panel. I'm not trying to short-cut process. I honestly want to know opinions.
 

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