So I want an FJ 40 but...

[metalshaper]

Here are a couple goodies going into this build.


I have 4 seats and harnesses. The heims are huge. I got these from one of the venders here. 39" BFG Krawlers on race line wheels, which I also got from someone on here.

Just need to get a few more "big ticket" items and I'll really be rolling.

 

[metalshaper]

Didn't get a bunch done today, just did some assembly of the parts. Mainly the rear tubs and bed sides.

I didn't fully spot weld everything together because as soon as I do, I would need to change something (duh!)

Also, you may or may not be able to tell, but the light gray areas on the flanges I sprayed with weld through primer. I don't really like using that because in my mind I feel anything in the weld pool is an inclusion, but I would rather take that risk than to have it rush through on me. Damn rust! I did that on any flange that was getting a mating service and spot weld.

 

[metalshaper]

couple more pictures.

 

[metalshaper]

So today sucked a little bit. I was so excited to get started working in the 40 I spot welded my pieces together before I finished the last step. $&!#%

Remember the earlier post, where I said I don't weld everything fully just yet, this is why.

The bad thing about buying good tools it that when used correctly they really work. 7 spot welds just to hold it in place took me an hour or more to get free. I can't remember if I said this, but the spot welder with spot up to 3/16" material.

 

[metalshaper]

And a couple holes. I've since fixed them.

 

[metalshaper]

So I used a hammer and dolly to smooth it back out, make the last bent and start adding the side supports for the edge

 

[metalshaper]

I folded a part of it over so you guys could see the plan of attack. You have to work the edge slowing so you can get it turned 90 degree then all the way over. Basically a hem joint

 

[metalshaper]

The next part that I started working on is the corner upper shape as it fades as it rounds the corner. This to me is the hardest piece. I'm not done with it but I wanted to give you guys a look at the process. It starts out rough and you have to continue working it. It's ok if it's not perfect at first. Sheet metal is like clay, you have to work it and it will flow just like clay. I welded the upper edges together so it didn't move so much that I couldn't get a good shape while I worked it.

 

[ChristmasMud]

You are a bold man and very gifted. Interested to see this finish.

 

[tnkayaker]

Love it. Can't wait until your next update.

 

[yohavos]

Absolutely incredible. Sub'd for sure.

 

[Stumpalama]

Incredible!

 

[Flipper1938]

Killer project. You are definitely jumping in with both feet. Keep posting pics!

 

[cwwfj60]

this is awesome!!

 

[GW Nugget]

How long has this project taken so far up to now?

 

[Mace]

You fit your name very well

 

[metalshaper]

How long has this project taken so far up to now?

The first one always takes the longest. Making dies, wood forms etc. This is the second one that I am building and so I had the dies made already but I did have a few forms I had to make.

Not as many as you think.

 

[65swb45]

Really happy I fell into this build thread. Amazing work.

One question. Did you intend to put the dimples on the wheel well tops upside down? It certainly facilitates getting an angle-iron based roll cage flush to the sheetmetal.

 

[metalshaper]

Really happy I fell into this build thread. Amazing work.

One question. Did you intend to put the dimples on the wheel well tops upside down? It certainly facilitates getting an angle-iron based roll cage flush to the sheetmetal.

Yes, I did that on purpose for two reasons, first because I wanted it to look different, second I wanted to make sure people knew that I fabricated the pieces. I have had a number of guys in the shop ask me where I bought the pieces. Then as I explained that I made them you could see the amazement on their face. It's almost a double whammy, first they see it in raw steel,"man that looks great!" Then they learn I made them by hand and its,"Holy cow I thought you bought those panels!!"

 

[65swb45]

Yes, I did that on purpose for two reasons, first because I wanted it to look different, second I wanted to make sure people knew that I fabricated the pieces. I have had a number of guys in the shop ask me where I bought the pieces. Then as I explained that I made them you could see the amazement on their face. It's almost a double whammy, first they see it in raw steel,"man that looks great!" Then they learn I made them by hand and its,"Holy cow I thought you bought those panels!!"

...and when you start retailing them, everyone will know who made them!