Build The Sheepdog this thing is hairy! july 1977 blue fj40

[Dagha Boy]

Damn! I was hoping you would make a hump. That was my nemesis.

 

[secretsquirrel]

Yeah the hump is a pain. Requires a hard forming tool and a lot of tonnage to form it. I think I will have to a weld a brace to the weak point. We will see Ill jump on it tonight.

 

[White Stripe]

Wow you have done a lot of work to this thing!

 

[Dagha Boy]

I ended up making just the hump out of fiberglass. Hated doing that but it was the only way. It appeared to me that the floor panel got its strength from the shape of the bump which in my case was now a piece of fiberglass and the joint between them right at the stress point. With the added problem of the seat mounting point outboard of the stress point.

I ended up putting in a brace running along the edge of the replacement steel floor and the hump where they met, and then a brace from that running up inside the hump to mount the seat onto. That way I could confine the fiberglass to the hump only.

Perhaps a similar brace will work for you. I tested mine by jumping on it repeatedly. No cracks no movement.

 

[secretsquirrel]

Oh the hump in the passenger side floor. I thought you were referring to the hump in the step support. It was way easier to get one from Real Steel.

 

[secretsquirrel]

the supports came out this evening. I gonna keep on plowing away.

 

[secretsquirrel]

160 holes drilled today. Most of them in the wheel well supports. The rest were in the tub for the roll bar, jump seats and the jack rods mount.....jack rods is that their name? but yeah ready to get those supports welded in probably on Monday.

 

[secretsquirrel]

Got half of the supports welded in. Didn’t feel like staying out in the 45degree garage any longer. Drilled out and primed the jumps seat bolt plates. Hey moving forward is moving forward

 

[secretsquirrel]

seat support plates welded in. then on to the dreaded hump. well it comes back to haunt. So i’ll have to cut and hammer out the new shape to match the transmission hump! It never ends lol. Anyhow it gives me a reason to buy new tools and work in the garage. So it not really a reason to complain i guess. As with most things its more about the journey then the destination.

 

[secretsquirrel]

Well looks like s*** next to the new rocker panel so. It was flakeing rust all along the bottom edge. I m making a new one.

 

[secretsquirrel]

This is the current situation. Was able to bend up panel. Hope to get it tacked in tonight after TACOS!

 

[secretsquirrel]

Attached as according to plan.

 

[secretsquirrel]

Made up the driver side portion of the cowl. A few pics of how i made the part that zigzags in. welded then sanded down the welds to be smooth. Cut out the offending rusty panel. sanded the rust off and sprayed it with weld thru primer.

 

[secretsquirrel]

Made up the driver side and got it welded in. Picked up 2 wiring harnesses one to restore and the other is jacked up. So i’ll steal parts off of it. That is for another time. Working on those pesky rocker gussets. that jog in there is a fun one.

 

[secretsquirrel]

first attempt at pesky bracket

 

[secretsquirrel]

took on another spot. Rust had eaten thru the outer skin. So another mud member had cut these off of a tub he was scraping. Come out pretty clean looking.

 

[secretsquirrel]

Also got the lower drivers cowl panel welds sanded and the mounting hole drilled for the fender.

 

[secretsquirrel]

Got the stupid rocker bracket bent up. It fits up good. I did make a few extra if anybody needs some. Primed then and will get them welded in tomorrow. Also fitting up the seat frame kit i got marking sure it fits with the shielding around the gas filler hoses. It does. Just plowing along

 

[stuxtruth]

Super inspired by your build! You sir are a true craftsman.

 

[SteveH]

A whole lot of very nice work here - good job! Great photos, too.