1999 Tacoma-rust repair...fixing bodges!

  1. jpmillermatic

    jpmillermatic Member

    Messages:
    785
    USA-NY
    Clean up continues on the DS inner fender area. I cleaned the rust off the mounting area for the inner fender bracket, and unfortunately found another area of rot in the lower back corner....Ill have to repair it from above as there are two crossmembers in the way from below...

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    DS panel cut to shape and that looks promising. Its nice to know that Ill be working with fresh metal now!...
    The big question of my day today, was, Can I replicate this rusted inner fender bracket from a paper template and some old truck bed flooring?...If I get the flat shape right, it should work, right?

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    Here they are after a bit more shaping of the new piece. I got my shrinker/stretcher out hoping it would do the trick....

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    In short...no dice!...the bracket has a couple of compound curves to it as it mounts to the underside of the inner fender on one end, and up on the side of the inner fender on the other...all fitting along a curving and sloping inner fender...So, out came the grinder for a pie slice approach...which in the end got me there...but it took the better half of the day to finish it up....

    It seems I can replicate brackets if I really have to...but I wish I could go to bracket wizzardry school. (Binky School!)

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    Gas tank is now painted with satin black, bedliner material and undercoating...that should do it!

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    not too bad for the day....but that bracket gave me pause.

    JP
     
  2. Pigeon_Droppings2 Member

    Messages:
    1,915
    Location:
    london
    Looking very good....is this turning into a full restoration :clapping:
     
  3. slim_boy_fat

    slim_boy_fat Forum Supporter

    $153 :scared:
     
  4. jpmillermatic

    jpmillermatic Member

    Messages:
    785
    USA-NY
    Im trying to keep that from happening!....I told my buddy that for our own sake I will not even glance at anything farther forward that the front edge of the truck bed!

    ;)

    JP
     
  5. jpmillermatic

    jpmillermatic Member

    Messages:
    785
    USA-NY

    75.00 US, plus 15.00 for shipping.

    aftermarket is around 30.00...but I know this will fit perfectly and last a long time.

    JP
     
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  6. jpmillermatic

    jpmillermatic Member

    Messages:
    785
    USA-NY
    Another fairly productive day....After going back and forth from the garage to the truck one too many times, I enlisted the help of the garden tractor to help move the little beastie. Now its quite close to the garage doors...big help now that I'm working on the frame again....(sorry for the blurry picture)

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    The crack in the frame was surrounded by very very thin metal, so a good chunk had to go...of course there is a bracket for the gas tank strap right there, as well as another hole for one of the lower cross member bolts...so after scratching my head a little, I decided to cut the chunk out and remove the bracket carefully for reuse, and measure the hole's location...you can see my chicken scratch on the folder paper behind the brackets....(you can also see other evidence of previous patchwork)

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    and cleaned up with some galvanizing primer sprayed on...

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    And the patches...one for the frame here, and the other one for the front bed support that I discovered was rotted through on one side....ahh, the joys of doing this kind of work....

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    How the bed support rotted like this is a mystery...except maybe for moisture forming inside the sealed cavity and just rotting it out from the inside...

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    take the patch and bracket, orient them correctly (after several tries!...I was hungry!).....

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    and we have something like this. I still have to weld the bracket in place and mark the hole for the crossmember bolt....I want to weld the bracket on before putting the patch in..very hard to reach afterwards...

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    Heres the patch welded in for the bed support...

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    I did get some primer and paint on there before it started to look like rain....which it did!

    I also decided to drill a hole in the bed support on the outside panel. This hole leads to the repair area cavity. I sprayed some Fluid Film in there and will use a plastic plug to cover the hole...

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    Close up of the hole with the fluid film inside...this stuff does smell for a few days....but Ive used it on my other vehicles and it does a good job...

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    Hopefully Ill get that other patch welded in this weekend...then the crossmember can go back in place....

    thanks for looking

    JP
     
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  7. jpmillermatic

    jpmillermatic Member

    Messages:
    785
    USA-NY
    A bit more done after work today...got the trailer hitch and more of the frame done...little by little!

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    I'm planning on getting that frame patch welded in tomorrow..that will be a big step forward...

    JP
     
  8. jpmillermatic

    jpmillermatic Member

    Messages:
    785
    USA-NY
    Bracket for the frame repair done!.....I got the gas tank bracket mounted to the frame patch:

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    drilled the hole for the crossmember bolt and set it in place, ready for welding:

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    Here it is buzzed in from the top side. I cleaned up the welds where the bracket needs to sit:

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    and from the bottom side. I decided to double weld this patch as it is structural: (When does a welder get up and start dancing wildly?...why, when he forgets to close his jacket and is welding upside down!)

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    Very happy that's in...Then I turned my attention to a bit of fun...finished up the trailer hitch, and though ironically, the hitch is rust welded in place, I added a new lock pin, cause it shiny!

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    and cleaned up the DS brake drum, then gave it a few coats of matt silver.

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    I'm happy with that!

    JP
     
  9. jpmillermatic

    jpmillermatic Member

    Messages:
    785
    USA-NY
    I was hoping to tackle that brake proportioning valve bracket today and simply cut all the mounting bolts and drill out the remnants...

    This is how it looked. You can see the assembly on the frame...

    [​IMG]


    well, thats what I was hoping for...but the truck had other ideas.....this was one stubborn assembly!...it took quite a while to prize the unit off the mount and when It did finally give up, I found that the mount welded to the inside of the frame was pretty much gone too....aaaaand found another crack in the frame. Thats what I get for painting the brake drum and having a little fun...

    heres the old and new valve bracket:

    [​IMG]

    and the toasty valve mounting surface on the frame....( I had already cut the bottom rot out thinking I could just patch it...but there was so much rust and scale inside the mount, I decided to cut the whole thing out...

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    aaannnd look what I find inside the frame rail......oops a pretty big hole.

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    Because of the complexity of the part, with all its weld nuts and mounting holes, I decided to fix it instead of making a new one...not sure which one would have been better in the end....

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    and from the backside....it still looks pretty crusty, but the metal is solid towards the top...just needs a very good cleaning and rust treatment....

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    Sorry for the blurry photo...a new space in the frame where some rot used to be...

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    The frame piece Ill have to replace with new steel. I think Ill reuse this bracket too...it needs a small patch on one side, but is okay otherwise...

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    On the bright side!...our new used crossmember came in and it is in fantastic shape!...I'm very happy with that!

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    thanks for looking

    JP



    JP
     
  10. jpmillermatic

    jpmillermatic Member

    Messages:
    785
    USA-NY
    soldiering on....got the bracket off the frame section and sorted out. that little rotted section on the bracket turned into both sides and the bottom...(murphy is visiting for a while apparently!)

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    cleaned up and mounted to a new frame section

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    and in place ready for welding.

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    Next up, Ill get that section welded in and begin fitting the brake valve mount...

    thanks for looking

    JP
     
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  11. jpmillermatic

    jpmillermatic Member

    Messages:
    785
    USA-NY
    A bit more done this afternoon...

    buzzed in the repair section

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    primed the mounting bracket

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    and set it in place for welding...which I did get finished but it got too dark to get good photos....

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    The little magnet with the handle is really powerful and quite useful..my go to!


    thanks for looking

    JP
     
  12. Pigeon_Droppings2 Member

    Messages:
    1,915
    Location:
    london
    Turning into a bit of an epic build this one.

    I remember on the Figaro project I just kept finding more and more problems....then when I thought I had it under control another curve ball would hit me in the head.

    Got there in the end of course...as you will too very soon by the looks of the great progress.
     
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  13. jpmillermatic

    jpmillermatic Member

    Messages:
    785
    USA-NY
    I am in the midst of just that, PD2. Makes me scared to just look at the thing. Today, working on the last DS gusset, I blew through a spot that ended up needing new patch which took up most of the side face of the gusset. My plan was to replace only the rear section of it so I left it in place. I will likely have to patch the front side face as well...oh well, little by little, right?

    Today was a good day,

    Heres the brake valve frame gusset with all voids filled in and ready for paint. You can see that last gusset to the right....

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    Some metric bolts and nuts were purchased at the local hardware store which has two isles floor to ceiling with just what you need and more!

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    Got some paint on a few of the suspension pieces...rust converter, primer, satin black and then some bedliner material

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    Freed up the parking brake system, which was a bit crusty and stubborn in places. the adjustment is under the cab, as seen below, this took some patient nut turning with penetrating oil, and back and forth spinning of the nuts until I had room for adjustment. works great now.

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    Brake load sensing valve back in place on a new gusset, bracket and all new hardware...camouflaged to look like it has never been touched! (irony?)

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    Rear of the frame on both sides is now done.

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    and I gave the muffler a coat of galvanizing paint...it seems to work great. the muffler on my Dakota still looks newly painted and that was done last year.

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    I still have that last gusset to repair, the diff. locker actuator to reinstall and the gas tank/skid plate to put back in place, then this side is done from the cab back!...wahoo!

    thanks for looking

    JP
     
  14. jpmillermatic

    jpmillermatic Member

    Messages:
    785
    USA-NY
    Progress was pretty good today, 2 steps back kind of thing...

    That last gusset on the Drivers side probably should have come out to repair it...but I did it in situ...its only time, right?

    arrggghh...

    here it is finished, though, so thats good....

    [​IMG]

    and, moving on to the other side of the frame, I needed to cut this gusset out, remove the bump stop bracket, and replace the section of frame....it turned out to be just as bad or worse than the first side, but thats okay as I am now familiar with the process. Ill replace this gusset with new metal as nothing attaches to it, and its placement is not critical to anything....(thought it will be going back in the exact same place)

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    Cut the gusset out

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    assess where to cut the frame & remove it with the bump stop bracket attached

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    cut some new metal for the frame and make up a CAD template for the gusset...

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    Hopefully I can get this section done tomorrow morning and that should finish up the welding on the frame!

    thanks for looking

    JP
     
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  15. jpmillermatic

    jpmillermatic Member

    Messages:
    785
    USA-NY
    A quick note about the Toyota frame recall/buy back/class action thing: There was something done for owners of 1995-2004 trucks with a reimbursement program and in some cases a buy back program. There was no frame replacement program on those trucks...by the looks of the condition of some of the metal, perhaps there should have been. I have seen videos of some 2004 and up trucks getting replacement frames at the dealership. what a mess. in one video, the forklift comes and takes the old frame out and stacks it neatly with at least 10 others!

    There have been horror stories where folks have gotten new frames, and they fail too!...

    I think this truck comes in before the debacle really hit the fan with all the class action suits...

    at any rate...

    I forged ahead with expectations of getting the cab buttoned up today, but again, the truck had other ideas. For starters, the crossmember will not go in unless I disconnect the brake valve, PS shock and drop the exhaust!...so that was done. the crossmember JUSSSSSSST fits in its opening...there were several moments of shear doubt and plans to use dynamite......but after all the components were relocated, all was good. dodged one there.

    so on to the progress, or to use the analogy again.."One step forward...."

    Here is a little patch I decided to weld in on the DS where I was sure water and debris would find its way in to the closed section of the frame when things get wet. its all sealed up now....This was impossible to get to before I removed the crossmember.

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    Back on the PS, here are the 3 pcs for the bump stop area...the repaired bump stop, new frame piece, and new gusset (the CAD template worked great on this piece. I scored the metal and then heated it up with a torch and bent it in the vice with a 5lb persuader and a cold chisel)

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    The frame piece and bump stop will get welded together like so...

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    and the gusset goes in like this

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    The gusset got 4 plug weld holes drilled in. Ill use these to set it in place for the rest of the welding....which will be seamed along the bottom and up both sides.

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    The frame had 3 small areas to repair..two from rust and one factory rectangle that was open directly to the inside of this assembly. not sure if it promoted air drying, or caused some of the rust as its right behind the tire.

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    inside the frame in that same spot. I welded both sides of the repair for peace of mind.

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    And heres the bump stop and frame piece ready to go back in....

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    and all in, cleaned up and primed...save for the gusset.

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    So, here is where the "two steps back" part of the analogy come into play....looky what I found while cleaning up the frame ahead of the last repair getting ready to put the crossmember back in place...

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    Yep, I had to cut these two panels out as they were paper thin toward the bottom of the frame. I must have scooped, vacuumed and blown out a pound of rust and debris...I just could not leave it the way it was, even though it looked okay from the outside except for two tiny little rust spots......is there such a thing as "Two giant steps back?"

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    So the plan now is to direct all my attention to this area..Ill have to get creative. and go a bit outside my comfort zone. if you look closely, you can see two holes in the frame just above the leaf spring mount. I will probably open the frame side up and bend it back to get to that area. if I have to remove the leaf spring, so be it...but I have dealt with leaf spring bolts before!...could be a problem if its frozen in place. but I'm optimistic..can you tell?

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    wish me luck!

    JP
     
  16. jpmillermatic

    jpmillermatic Member

    Messages:
    785
    USA-NY
    I decided to explore the new repair area and see if I could find a rarity....good steel!

    and I eventually did, which I'm quite happy about. Its not as bad as it could have been. In fact there are traces of a sort of rubberized paint and clean steel on the inside surfaces of the frame. good stuff there.

    Heres the stuff I had to cut out.....

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    and a "wee pile o rust"

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    The area is now defined and I can reach the holes inside the frame from within. They are on either side of the rear part of the leaf spring bracket which is still quite solidly held in place by good metal. whew! Ill clean this up quite a bit more, weld in some repair patches inside, treat the daylights out of it with rust converter, etc, then get the new side panels welded in place.

    [​IMG]


    Then, it started to rain on my parade, so I moved operations indoors where the bed was waiting patiently for me to get back on it.......

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    Here is the inner rear quarter.....it cleaned up quite well in this area.....with only a small repair section needed...

    [​IMG]PS lower quarter 2 small by jpgraphics2012, on Flickr

    [​IMG]

    and the repair piece ready for welding tomorrow......I wanted to use some original metal from this truck and found a small section from where I cut the fender arch out....of course I had to clean the bondo off it!

    [​IMG]


    all in all, good progress...back on track, I guess!

    thanks for looking

    JP
     
  17. jpmillermatic

    jpmillermatic Member

    Messages:
    785
    USA-NY
    It took a while for the fog to clear out and everything was soaking wet for most of the morning...so I kept going inside until around mid morning.

    I finished off the lower rear quarter patch and it came out pretty good...I welded both sides, so felt more confident in getting the welds ground down a bit more on the front side.

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    I took a look at the other lower quarter on the drivers side, and it was "repaired" the same way...metal patch over rusty metal, and it too was bubbling. I'm still amazed by the good body work and paint by the previous body shop, but the rust repair was just not done to last. I mean you can still see the old rust hole on the inside of the piece I cut out.....

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    I used some of the repair panel sheet metal left over from the fender arch for this piece...you can clearly see my somewhat crude hammer marks...I guess a rubber or plastic mallet would have been a better choice. I opened the vice a little, layed the piece in the open jaws and hammered out the rough contour. The shrinker tool helped add the curve to the flange.....

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    rough trial fitting with the fender liner in place....looks pretty good so far.....

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    I really don't have much else to show for todays work....I really felt like there should be more...though running out of mig wire didnt help, and there was a bit of paperwork to do.....

    thanks for looking

    JP
     
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  18. arther dailey Member

    Messages:
    3,128
    Location:
    Southampton England
    Great work on the truck , your neigbours lucky to have a good neighbour rather than local bodger , also loving that dry stone wall in the back ground ..really nice , Arther
     
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  19. jpmillermatic

    jpmillermatic Member

    Messages:
    785
    USA-NY
    Thanks, Art

    I try to keep things above bodgery if I can. Best thing about these forums, of course, I'm always learning! Inspiration is never too far away and it certainly is a challenge to get even close to some of the work I see here on this forum!

    Stone wall was done by a very proud previous owner of the house. Its actually mortar skillfully mostly hidden from casual sight. One other nice thing about it...no block on the inside...so its solid stone throughout...we pinch ourselves regularly as it came with the house...never would have the funds to pay for one to be built now!

    JP
     
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  20. arther dailey Member

    Messages:
    3,128
    Location:
    Southampton England
    Well he did a cracking job of it eh:)
     
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