The Resurection of 'The Beast'

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Thanks Felix!

I ordered a Toyota Center Arm Rebuild Kit today. This will hopefully take some slop out of the steering. I am also going to fab up a rear tire mount with some Iron Pig parts later this month and replace the passenger A-pillar body mount also from Iron Pig but custom fabbed!
 
I was able to get in two good days of work this weekend thanks to the wife. My bday is this week so she is taking care of things around the house so I can have a few evenings to work this week! :bounce:

I only got about a third done this weekend of what I had planned to complete but that's OK. I was able to totally reconstruct the inner fender area on the front passenger side. I have included a bunch of pics for your viewing pleasure!

Pic 1) before work started - there is a pic back in my thread of the rust before I cut it all out. I had six separate areas to reconstruct.
Pic 2) first patch in
Pic 3) second patch in
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Pic 10) third patch welded in with lip bent - simple using vise grips - I still have to drill holes to attach the upper fender. I have the spots marked in the template I created. I am going to wait to drill until I finalize the fit on the upper fender.
Pic 11) fourth and fifth patches welded in and sixth patch tacked in. At this point I ran out of welding gas and had to drive 40 mins one way to get a refill. :mad: Soon after I ran out of wire and had to get more. Luckily a shop w/ wire was only 10 mins away.
Pic 12) All patches welded in and metal prepped for POR15. I didn't get a chance to put the POR down yesterday and this morning some flash rust has appeared. I'll probably knock the top of that off w/ a brush and rinsing before I POR.

I hope this evening to get my wheel well patches prepped for POR and the driver's floor patch prepped also. By the end of the week I hope to have the driver's inner fender patched up (the work needed on it is much less than the passenger side) and then I will POR everything at the same time.

Enjoy! :cheers:
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Dude, I am sooooo envious of 2 things: 1. your rig...awesome! and 2. the work you're putting in, one day when I'm big I want to be as good and patient with metal work as you.

:D
 
I didn't get too much work done yesterday. A neighbor is building two houses near mine - one beside and one across the road. I let him know that I would pull my truck inside at night now so any buyers wouldn't be chased off by my Piggie :doh:. I did get the rust hacked out of the driver's inner fender well and one patch cut to fit. I hope to get the other two patches I need cut to fit today and tacked into place. I'll post pics after tomorrow.

Here is a quick question (you might want pics to answer). I have a few various places where factory sheet has rusted through but these areas can not be seen easily (under fenders), can pretty much be 100% coated w/ POR and these areas don't have any impact on my Pig's structural integrity. Should I just slather POR over these areas or while I'm at the body work go either POR then weld a patch over or cut these areas out and then patch. I would like to just POR them since most of them are in some pretty hard to reach or complicated to patch areas.

ETA: Received a center arm rebuild kit from the Ralph Hayes Toyota yesterday. I'll install this weekend after next.
 
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I got a couple hours in the past two evenings but last night after about half an hour of welding the skies opened up. I wasn't too upset since we are in a drought. I pulled in my equipment and drank a PBR while watching my Piggie get wet. I do have the passenger inner fender all welded up. I need to put a slight lip on the sheet to match stock and then trim to fit. I plan on doing that this evening, prepping for POR and maybe,,,just maybe getting some POR down.
 
yooper said:
I think I'd just do the POR or even just cut those pieces off if they don't have a function...
Click to expand...

I'll post some pics tomorrow of the holes. They are in the inner fender well. All they do is allow air to pass through. I have some appx 1 inch by 1 inch pieces of 16 gauge cut to weld over...still undecided if I'll weld and POR or just weld. I want to close the holes up but I think just applying POR will help with the rust better since I'll have better access and won't have to worry about burning the POR off with the welder.
 
Pic 1) these are the holes I was talking about...to POR, POR then weld over new metal...its gonna be a pain to cut everything out and replace with all new metal...I'm leaning towards slathering POR and letting it be
Pic 2) DIY spindle for rear tire mount from IPOR
Pic 3) Custom fab'd body mount from IPOR
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