Sill Wars

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77mustard40

77mustard40

SILVER Star
Joined
Nov 28, 2010
Threads
57
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2,751
Location
Austin, TX
Since there are two 40's undergoing similar body work I thought I'd start Sill Wars. Today was the initial day of metal work at Colvin's and here are the initial photos. My scope of work is rear sill replacement, quarter panels and bed up to the rear heater. THe front carpet is staying but I have pulled the seats with mounts, rear heater and anything else such as the console to keep me busy while the pros work. We will see how the rattle cans look next to the finished product.:hhmm:

I will try to post regularly through the process.:wrench:
starting ds.jpg
starting ps.jpg
starting sill.jpg
 
End of the day today

Here she was this afternoon
pm ds.jpg
pm ps.jpg
pm sill.jpg
 
Kelly, I'm ready to concede defeat in the sill wars. You'll catch me by Friday and leave me in your dust by next week.

Your rear quarters look very solid in the pics. Some of the best I've seen in fact. Are you having them patched or replacing the entire panels? We're just welding in patch panels on mine. Similar to these, but not from Cool Cruisers--

coolfj40_2155_186403429
 
Sea Knight said:
Kelly, I'm ready to concede defeat in the sill wars. You'll catch me by Friday and leave me in your dust by next week.

Your rear quarters look very solid in the pics. Some of the best I've seen in fact. Are you having them patched or replacing the entire panels? We're just welding in patch panels on mine. Similar to these, but not from Cool Cruisers--
Click to expand...

Lee, I think my panels are fine. The only rust other than what was cut out was where there are now holes in the second picture of the second post. Passenger side had damage and bondo from the PO, picture is not too revealing because it was so bright out today. Basically they drilled through the panel where the rust was and will weld it up and grind it out. As far as the old dent they were able to hammer and dolly it out and it looks amazingly straight, wish I could do this stuff.

It will be slow process though, don't expect the sill for a week. Just thought it would be cool to compare the process for two rigs at roughly the same time.
 
77mustard40 said:
It will be slow process though, don't expect the sill for a week.

Just thought it would be cool to compare the process for two rigs at roughly the same time.
Click to expand...

I just noticed your sill is different than the one we used. Apparently the design changed to a one piece unit in 1979. I don't know if that's a good thing or not. MUD's consensus (see the thread DaveG linked) is that Toyota did a very poor job at engineering the sill-bed floor juncture, almost guaranteeing rust. Where is your sill coming from?

We're waiting on a DS fender and rear quarter panels, and haven't even started on the outer rockers. Probably won't see any additional progress until next week. I'm 100% certain my truck won't be finished by June 1st, which was the original estimated completion date. Possibly mid-June. Definitely July4th. :rolleyes:

Keep those inspiring photos coming. :cheers:
 
Sea Knight said:
I just noticed your sill is different than the one we used. Apparently the design changed to a one piece unit in 1979. I don't know if that's a good thing or not. MUD's consensus (see the thread DaveG linked) is that Toyota did a very poor job at engineering the sill-bed floor juncture, almost guaranteeing rust. Where is your sill coming from?

We're waiting on a DS fender and rear quarter panels, and haven't even started on the outer rockers. Probably won't see any additional progress until next week. I'm 100% certain my truck won't be finished by June 1st, which was the original estimated completion date. Possibly mid-June. Definitely July4th. :rolleyes:

Keep those inspiring photos coming. :cheers:
Click to expand...

After seeing your initial photos I met with Mike and Phil and we decided to purchase the sill from CCOT. The initial plan was to fab the sill cover and leave the structual part of the sill in place but I was more comfortable in buying the part and dropping it in. Now that they are into the project and can see what they have I think they agree.

My sill will come next week and so I'm guessing mid-June as well. I will try to shoot some picks of the interior parts I'm working on in the garage. We will have to plan to get the two together when they are done.:beer:
 
what are these repairs costing ya'll (ball park)? the '80 we have here is done as of two days ago and it turned out nice but it was a LOT of work. we replaced both side's from the front doors back along with the rear sill. if ya'll around the shop some time stop by and look at it. i would like to also see ya'll when there done. Lee it looks like nice work from the pics.
 
green grass hopper said:
what are these repairs costing ya'll (ball park)? the '80 we have here is done as of two days ago and it turned out nice but it was a LOT of work. we replaced both side's from the front doors back along with the rear sill. if ya'll around the shop some time stop by and look at it. i would like to also see ya'll when there done. Lee it looks like nice work from the pics.
Click to expand...

Sea Knight has a larger scope than me so he might have a tougher time breaking out the cost. I'm expecting to be just north of $2,500, we will see:meh:
 
Pickup

Tucker, let me know if you need my pickup
 
green grass hopper said:
Lee it looks like nice work from the pics.
Click to expand...

77mustard40 said:
Sea Knight has a larger scope than me so he might have a tougher time breaking out the cost. I'm expecting to be just north of $2,500, we will see:meh:
Click to expand...

Thanks Edwin. These guys do excellent work. I'll bring the old beast to your shop when it's done.

Kelly is correct about the difficulty breaking out cost. As you know, I had a wreck, actually a rollover. A lot of the repairs are due to the rollover damage. I decided to have the rust repairs done at the same time so the cost is all lumped together.

I bought the floor pans, inner and outer rocker panels, rear sill and corner channels separately. I also bought the turn signal lights and some other parts I can't remember. All of that cost around $1800.

The original quote for body and paint work, including installing the new sill and body panels, was a bit less than $10K. Fortunately I was able to cut a deal where they allowed me to work in their shop. I did most of the disassembly and when they're finished, I'll have to put everything back together. Doing the grunt work is saving me around $3K.

My tab from the body shop will be $6700. Add the $1800 I already paid for parts and the total will be around $8500. :crybaby:
 
today's progress

Here is the driverside panel where I had a rust hole all the way through. New 16ga. welded in and ground out. Underside shows the patch in place.:cool:

The cover panels have ben fabricated so now I'm waiting on the sill. Also the body mounts were shot so I ordered a kit tonight so I will have all the mounts needed for the whole truck when it comes time for the rest of the story.
DS QP old rust hole.jpg
back side of plate.jpg
patch plates.jpg
 
and in the garage at home

Here are a couple of shots of the seat hardware before and after a lot of wire wheel, sandpaper, navel jelly, priming and painting. Console was disassembled and run through the mill as well.

Still have rear heater to rebuild and gas filler and evaporator covers to clean up and paint as well. Hope to get this knocked out this weekend.:beer:
seat before.jpg
seat after.jpg
console.jpg
 
77mustard40 said:
Here are a couple of shots of the seat hardware before and after a lot of wire wheel, sandpaper, navel jelly, priming and painting. Console was disassembled and run through the mill as well.

Still have rear heater to rebuild and gas filler and evaporator covers to clean up and paint as well. Hope to get this knocked out this weekend.:beer:
Click to expand...

You're a man on fire.:D :cheers:

I need to do the same treatment to my seat brackets. Maybe your pics will be the inspiration I need to get started.
 
Sea Knight said:
You're a man on fire.:D :cheers:

I need to do the same treatment to my seat brackets. Maybe your pics will be the inspiration I need to get started.
Click to expand...

It just seemed like the time to do this, plus there is a big hole in the garage so I thought I would take advantage of the workspace.

Be careful, :princess: asked me the other night if "we were turning into one of those couple"
 
77mustard40 said:
Be careful, :princess: asked me the other night if "we were turning into one of those couple"
Click to expand...

Ha, we've all been there....here's a story for you. I won't name names in order to protect the innocent. A new WALCS member (and new FJ40 owner) returned home from attending their first Friday meeting at Billy's. That individual had guessed at being home no later than 6PM. The meeting ran longer than expected and their arrival home was closer to 7PM. This person was greeted at the door by an irate :princess: who's first words were:

"Is this how it's gonna be, with you and those people?" :lol:
 
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