the DSRTRDR is getting some TLC . . .

[Tools R Us]

Pitchers?

Had a couple of issues to solve before mounting the rockers. Two places that needed bolts, had no metal to screw them into? There was no there, there.

 

[Tools R Us]

The rear one also had a crack on the rocker panel side, was able to weld it. Made a new piece for the quarter side. Tack, cool, grind, repeat.

The rocker side was unsupported, had movement, floppy, likely the reason for the crack. Welded the lower part solid, where it will be hid by the new rocker, then made a small angle support and tacked it to the tub cross member, now it's all solid.

 

[Tools R Us]

Opened the front one, found a treasure trove, a lot for a small hole? Cleaned it out, treated with phosphoric acid and slobbered paint in there.

 

[Tools R Us]

Cut a little patch, tack, cool, grind, repeat. Had to be more careful with this one, that body line is the proposed end of the new paint!

 

[Tools R Us]

The next diversion was the passenger side fender, it had made rock contact, installing more texture than allowable. Needed to be straightened as much as possible, with as little damage to the "patina" as possible.

 

[Tools R Us]

Jigged up this precision, composite die, to apply pressure in the correct spots. Then applied repeated percussive force to the inside of the fender.

 

[Tools R Us]

That got it pretty close. Added a calibrated shim. Continued applying percussive force. Is a Chilean shim proper protocol for a FJ40?

 

[Tools R Us]

That got it very close, well within spec, it still has a bit of texture, so matches the rest of the rig! It's difficult to achieve this level of perfection without proper tooling, maybe?

 

[cruiserjunkie]

Won't even be close to the same machine she dropped off.excellent work

 

[Tools R Us]

Back to the new rockers, they are straight, unlike the body. Most notably, the quarter is at a differing angle from the rocker, not going to cut it! So, cut the rear part off and welded it back at an angle to match the quarter.

Using new Bushwacker flares, so, mounted the old ones higher and further back, where we hope they will clear the tires. This gave the trim line for the rockers.

 

[ChaseTruck]

That got it very close, well within spec, it still has a bit of texture, so matches the rest of the rig! It's difficult to achieve this level of perfection without proper tooling, maybe?

Would have probably been simpler(quicker?) to just tell her to go and manglebend the other side...

 

[Tools R Us]

Stopped at our favorite auto body store, picked up some trim strips, this one fits/looks the best? It's listed application is chevy trucks, someone should appreciate that? Drilled and installed button head bolts to secure upper edge of the rocker.

 

[Tools R Us]

Would have probably been simpler(quicker?) to just tell her to go and manglebend the other side...

Don't know, it was a pretty good trek to where that bolder is and not sure she could get the other side on it without rolling off of the cliff?

 

[ChaseTruck]

Don't know, it was a pretty good trek to where that bolder is and not sure she could get the other side on it without rolling off of the cliff?

Yes, but I would trust her to find another suitable boulder pretty quickly. I mean, when has she not?

 

[Tools R Us]

Yes, but I would trust her to find another suitable boulder pretty quickly. I mean, when has she not?

True, she has an impressive track record!

 

[inkpot]

True, she has an impressive track record!

Is the blue one up in Sycamore big enough to do the job?

 

[DSRTRDR]

Opened the front one, found a treasure trove, a lot for a small hole? . . .

 

[murf]

Wow - will she recognize it when its done?


Remember to save whatever stickers you can!

 

[DSRTRDR]

all stickers are gone - except those on the rear bumper, and more of those will go when the spindle for the spare tire carrier and the various rear lights go in

the seriously faded Red Rock 4 Wheelers stickers on the kick vents (the oldest on the truck) will stay

 

[cruiserjunkie]

Sorry to see the stickers go going to have to find a new way to give it some character with all the new body armor and no stickers