Thirteen Years Later

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So we got another Toyota product in the fleet. My son Jackson sold the Mazda to a friend and then picked up this Hilux Surf. He has already removed the running boards, roof rack and the bull bar and winch. Looks a lot cleaner that way.

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So I got the top off yesterday. Some rust but I've seen worse - actually I've seen worse on this truck :hillbilly:

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The roof is not too bad. I will take off the windshield bracket and blast it to see if I can save it. the rest of the metal around the top is not bad. Just surface rust on the bottom face when mounted. I think I might be able to straighten the gutters and just repaint. That would save doing the rivets - that's an adventure all in itself.

Anybody used the SOR headliner? It's them or CCOT I think. I've bought from CCOT in the past but was never 100% happy with the transactions, though I did always get what I ordered. I have a few things in the cart on SOR's website already so I think I'll grab the liner there.

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The four corners (top & bottom, left & right) of the tub to top joint have issues. This was a known issue a decade ago. I had always intended to go topless one summer and refurbish the top but never did. But the tub needs attention too so I guess it didn't matter.

Looks like I am going to be painting all the bolt on parts and the exterior of the tub. Trying real hard not to make it a frame off. Right now I can get through this in a few months over the winter but if the tub comes off she may never go back together by my hands.

Next session I will remove the seats to protect the new upholstery I have on them and the roll bar for ease of access to the patches on the quarters. If I find any rust in the floor I'll decide from there if the tub has to be lifted up off the frame. I did the floors last time so if anything it would be small spot fixes. Mostly I just don't want to strip the dash and heater out.

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Removed the double swingout I made. I don't think it's going back on. I need to order up some new OEM rear signals and hopefully a plug from @Coolerman to replace the one I cut off due to corrosion. Maybe some wire too. Stock tire carrier to go back on. And the bumperettes.

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I really like the idea of their stainless set, but it's 1/3 the size of the cadmium set. There aren't even enough 6×10 bolts to do the whole rear door hinges. Really you'd need 2 sets of the stainless.

But they aren't replying to my queries about availability anyway, so mayday be worth looking to source them elsewhere.
 
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RevISK said:
Would be curious about this.
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Actually, I think I was mistaken. I bought the tool to bend 1" square tube on the diagonal for my roof rack. The tool to bend straight like the grill guard was one I made. Both tools were used on an old school Hossfeld bender. Basically I made my own tool similar to the one shown on page 32 of their PDF catalogue. I called in a favor at the machine shop (sister company of my employer) to make the center 6" radius round tool and fabbed a backing block from 1/4" laser cut steel.
 
Chamba said:
I really like the idea of their stainless set, but it's 1/3 the size of the zinc set. There aren't even enough 6×10 bolts to do the whole rear door hinges. Really you'd need 2 sets of the stainless.

But they aren't replying to my queries about availability anyway, so mayday be worth looking to source them elsewhere.
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I may get some fasteners from SOR. They are not quite the right heads but at least they are 10,12,14mm and yellow cad.
 
tucker74 said:
I glued some charcoal gray automotive carpet to the inside of my cap, it looks and has held up better than any of the liners I’ve tried. Perfect time to do it with the cap off 😉
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I've seen that done before and it's an option. I will likely do that for the FJ45 custom build which is next on the agenda, or second to next. But for this one I am actually trending it back to stock. I've got lockers, winch, lower gears and a snorkel in this one but all of it is bolt on - I always intended to return this truck to stock. Even a stock bumper and, what were they, 28" tires originally? My 45 is going to be the full out custom.
 
Right now I believe I will start with the tub repairs first and build from there.
Windshield frame next.
At that point the rest can be done piece meal, one at a time to keep from being overwhelmed by the mountain of work.
Once the windscreen is on I can do the sides of the top.
Then the related bracketry over the doors.
Then the top itself. Paint the bezel at the same time.
Then the front clip starting with fenders - I have brand new OEM ones.
Aprons.
Bib.
Hood.
And doors can be done last.

Easy right?
 
Just as a i was about to ask where the blue cruiser went.... haha i remember it was in the garage that time i picked up a 45 headache rack from you. (Your brothers if i recall)

Nice to see the 42 living a good life! I broke the drag link rod on mine 2 weeks ago still waiting for replacement.
 
rkymtnflyfisher said:
Jumping right in to the deep end of the pool.
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Geronimo!

Chamba said:
Speaking of frames and frame-offs, how has your frame held up? Any issues at the rear spring hangers or in front of the rear spring mount where the frame turns upward?
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The frame is good other than the rear spring hangers are showing a little bit of rust jacking. I might swap them out.... creeping...creeping

Varty Yo said:
Just as a i was about to ask where the blue cruiser went.... haha i remember it was in the garage that time i picked up a 45 headache rack from you. (Your brothers if i recall)

Nice to see the 42 living a good life! I broke the drag link rod on mine 2 weeks ago still waiting for replacement.
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Yes, old blue is still here. It's loaded up with sheet metal to replace all the holy parts. That will be the third project after this one and a bit of work on my FJ45

I saw your post about the drag link failing - just entering the driveway, if I recall. Need to get yourself a lottery ticket with luck like that.
 
I was poking around in my Youtube account and found this old gem. I apologize for the shaky camera work, the camera boy was only 9 at the time.

 
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