- Thread starter
- #261
working on the passenger side hard top side
Builds The Sheepdog this thing is hairy! july 1977 blue fj40 (2 Viewers)
- Thread starter secretsquirrel
- Start date
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This is an absolutely super rebuild!! I have a '77 June build date--wish I had seen this thread before--went thru practically all the same panel repairs-esp the w/s frame, as you have done, but I didn't have the skills, or tools you have--this rig build should be a sticky for sure--
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- #263
Hey thank you for the kind words. I’m just doing what i can it’s not perfect. Just getting it close and having fun doing it. There are guys/gals on this forum that are head and shoulders above me. This forum has given me more information and inspiration then i can put into words. It’s a true treasure trove of information.
- Thread starter
- #264
So it begins
merbesfield
SILVER Star
I will be watching bc I have the same hole in my top.
- Thread starter
- #266
well got the caulking scraped out. sanded and punched out a number of rivets. weird thing is around where the pillar of the hard top comes up at the door jam there were a bunch of rivets like one every inch…. the rest of it had them on what seem to be the normal spacing 4 inches apart approximately.
- Thread starter
- #267
the pile of rust in the top after knocking out all the rivets. Second is the well riveted part above the door jam. Third is the rusty old frame gonna mark some reference holes. Then comes the new metal from CCOT. Fourth picture is front of the cap. Is this curvature normal? i’m wondering if sitting off of the forty for close to 8 or so years has cause warp age?
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- #268
Some dry fitting of the new metal. Waiting on a pair of the L brackets that bolt the windshield and door header together.Then try the fiberglass cap on to be sure. Then tack it together and pull it off and finish weld it up
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- #269
part of the gutter welded up.
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- #270
The top got welded and fiberglass riveted. Has not been painted. Ordered front door and ambulance door patches from ccot. There should soon be an update on that and
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- #271
Another piece that needs major attention. All doors need bottoms patched. Real Steel patch panels are being used here. Wish me luck.
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RevISK
SILVER Star
Sweet.
I’ve been tackling my hardtop repairs but with way less skill, far inferior tools and in an old dirt floor horse stable. You are inspiring.
Thanks
I’ve been tackling my hardtop repairs but with way less skill, far inferior tools and in an old dirt floor horse stable. You are inspiring.
Thanks
- Thread starter
- #273
Trim fit trim fit then measure and trim some more
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- #274
Then you tack
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- #275
continuing on making progress. Hoping get this one all buttoned up this week. then move to the other side.
RevISK
SILVER Star
Are those patches RealSteal or did you make them?
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- #277
The bottom sections are real steel. They fit pretty good so far, granted this is the first door of four that i have patches for. I will continue to give my opinion and thoughts on these panels moving forward. The sections about the standard real steel patch in my own making.
RevISK
SILVER Star
Thanks for the reply.
I have RS door patches for my front doors (have only done the DS) and they fit pretty well. I’ll need to do the ambi doors eventually and figured it was a given that I’d get RS for those as well.
I just wish they made a rain gutter…
I’m enjoying your work, thanks for sharing.
Ian
- Thread starter
- #279
Lots of stuff here to add. The hole location and weldnut size did not match my 77’s drivers side latch on bottom patch panel. Ordered some weld nuts from Mcmaster cart. The hole to secure the inner part of the latch had to be added to. Also had to cut out one of the hinge bolt holes cause it was stripped out. noticed that there is two layers of metal and a weld nut. This door is garbage but gonna see it thru. Like said before this is not a concourse restoration it’s more of a rusteration. Must people would have parted this thing and not thought twice.
I just read through the entire thread and I will say that (as a sheet metal worker, owner of a metal fab shop and former bodyshop/paint supplier) that your skill and perseverance is exemplary and uplifting. Beautiful FJ40 thanks to your hard work and considerable skills. I have restored several vehicles, some were in pretty bad shape but this time (getting older!), I chickened out and bought an FJ with an Aqualu tub and the paint and bodywork done.
Just had to add to the chorus of "well dones!"
Dave
Just had to add to the chorus of "well dones!"
Dave
