So I want an FJ 40 but...

[MScruiser]

Hell, I might be open to letting you borrow mine if I could trade you some work while you had it.

 

[metalshaper]

Hell, I might be open to letting you borrow mine if I could trade you some work while you had it.

Guess it depends on what you're needing.

 

[Bossman]

So this is the better of the two that I have. This one is around 1972 and I have an earlier one too if that's what you need.

 

[Bossman]

 

[Flipped Bezel]

You sir are a truly a metal magician!!

Subscribed.

 

[metalshaper]

ok, bought solidworks and in the process of drawing out the frame. I'll post pictures soon. This software is harder than it looks.

 

[metalshaper]

I know I've been neglecting this project, had a few MAJOR changes at the shop. Thought I would share some of those changes with everyone.

Over the last 3-4 months we have installed some new equipment. We bought an Amada LCG3015 Laser and the Amada CNC 150 Ton Brake.

The Lazer


The Brake



Once we get all the training done I'm hoping to get back on this soon.

 

[metalshaper]

Ok, I know there has been a long delay in this project. All the training on this new equipment has been crazy. However at night I have been taking my 2D patterns and turning them into 3D patterns and assembling them. It makes it so much easier to plan everything.

 

[metalshaper]

Well, after 2 years of starting this project I’m finally back on it. A lot has changed. I spent almost 400 hours redesigning this body in solidworks so I could assemble these bodies pretty quick. I also changed a from the thinner sheet metal I was using to 16 ga cold rolled sheet metal. I wanted the body to out last me and not be a tin can like newer cars are. I wanted it rugged, strong and good looking. On the next part of this journey you will get to see me start completely over and have a far better body. Also, if you will notice, you will see a ton of clecos being used. In my CAD file I added the holes for them so I don’t have to drill a single hole. Then as I run it through the laser, the holes are cut perfectly every time. Then I run it through the CNC press break to get my bends perfect every time. As you can see from the two pictures if coming together... again.

 

[metalshaper]

These next pictures I’m working out the quarter panels. Remember this will be a 4 door so adding in a rear door needs to look good. So I took inspiration from the Jeep JK and that is where I got the door shape from, partially.

Also I was testing if I should make the rear corner completely formed like a Jeep or go with stuck. The Jeep style is actually harder to make them the stick corner so I’m going with the stock corner.

 

[metalshaper]

Here is a picture of the stock style corner. It looks a lot better than the Jeep style also.

Now on to the door opening. I start with the outside opening and work my way in. Here are a couple pictures of it loosely attached to the rear tube.

Also, if you notice the pillars stick up taller than the rear of the tube. This is so I can run it through the toolings and cut off the extra.

 

[metalshaper]

On to the inner door assembly. As most of you know this gets put on the back side of the outer door skin. Unlike a Jeep this is double walled so it makes it crazy strong. I like it. I’m using clecos to attaché and test fit everything.

 

[metalshaper]

I had a problem turning the edge back so I could create the pinch seam. So I drew up this tool and cut it on the laser. Man this was a life saver because let me tell you, using a hammer and dolly of 16 ga cold roller is beast mode.

I’m getting ready to mate the two door skins together.

 

[metalshaper]

Work getting done

 

[metalshaper]

Got the two front door openings finished up so now I can start the rear.

 

[metalshaper]

Starting on the rear door opening. Should have that done tomorrow.

 

[offr0adlim0]

Speechless, I’m at a total loss of words. You Sir are an Artist...

 

[wngrog]

Very cool.


Now don’t wait two more years.....

 

[wct49]

d
a
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n

 

[metalshaper]

I also got the rear door floornpan made.