So I want an FJ 40 but... (1 Viewer)

[metalshaper]

Is there anything in your thoughts On a top, hard or soft...

Yes, both actually. Just haven't planned it out yet.

 

[47coeman]

That would so cool the best of both worlds. Any idea when this may possibly go as a kit or fabed together as it would be a strong consideration on my part.

 

[metalshaper]

That would so cool the best of both worlds. Any idea when this may possibly go as a kit or fabed together as it would be a strong consideration on my part.

I'm not sure yet, I am still building the fixtures for everything else right now. As soon as I get there I'll let you know. The fixtures for everything else just takes so much time but once they are done I should be able to build a full body from start to finish in 2-3 weeks.

 

[47coeman]

Any updates for us.

 

[GW Nugget]

Are you entertaining the thought of punching things out and selling them?

 

[metalshaper]

Are you entertaining the thought of punching things out and selling them?

Yes, and with this new update you will see why.

 

[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 outlast 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 tooling 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.

 

[boots4]

Awesome work!

 

[metalshaper]

Also got the rear door floor pan made.

 

[Bripars40]

Absolutely amazing. Looking forward to seeing the potential costs associated with your panels. I’m very interested!

 

[ceylonfj40nut]

^^^^^x2

 

[deliverance]

Very impressive. Dang!

 

[White Stripe]

Amazing! When u weld the panels together will u coat the two junctions with something so moisture doesn't get in-between the welds and cause rust? Is this gonna be for cruising around town or for offroad use mostly?