Rusty 1984 FJ40

[Flit]

Hi. I bought this rusty Landcruiser about a year ago. I bought it reasonably cheaply with heart throbbing and brain disengaged. Then along came Warrant of Fitness day (that's maybe called a Road Worthy Cert or similar wherever you are). Of course, it failed. Previous owner must have had a dodgy garage friend.

So, some weeks after riding a push bike to work the wife finally let me get a MIG welder. I'd been wanting one with the aim of fixing up that 1963 EH Holden parked next to it there in the garage. One could say I am stupid buying two rusty wrecks that can't be used on the road. Ha ha, they are probably right. I shall have to rectify the situation by getting them back on the road.

The aim is to get the Landcruiser back on the road legally asap. I have never had any panel working experience before (as will be obvious in this thread ha ha). The panel work I do on the FJ40 shall be a learning experience and shall enable me to do some more quality work on the old Holden when this is completed.

My pride & joy at the moment is the push bike - centre stage.

 

[Flit]

I've been at it during weekends for a couple of months now (prior to first post above). I shall do my best to bring this thread up to date.

I must apologise for the lack of continuity in the order of the pics. Sometimes I was so in the zone and plain forgot to snap what I'd done.

Here is the right rear top bit of hardtop, which was one of the the first bits I cut out. Here I am fumbling through the process of making the replacement.





The bit on the inside had to come out too.





The outside of this internal was bogged and below that bog: a sea of little dents. I removed the internal to access the outer layer with a hammer & dolly.



I'm not sure if I'd already hit it a few times, this photo certainly doesn't look as bad as I remember.





Ohhh, it's rusty too. Good job I cut it off.



Replacement patch:

 

[the snooper]

is that an old volvo with the wings off ?

 

[Flit]

Having removed the glass & rubber revealed ....rust! a little shoulder repair here to lower right corner.



This was an easy bit to make.





Cut cut cut...



and cut...



and weld and grind...



and hammer that pillar out as best I can...



Weld in the internal pillar section...



and grind...



Now I can refit this new bit...



Here it is after grinding & surrounding replacement bits...

 

[Flit]

is that an old volvo with the wings off ?

No, that's a 1963 EH Holden. Here it is when I still had it running...

 

[Flit]

Now to weld on that outer curved bit.



Hmm... not so beautiful as other repairs I've seen on internet forums, which incidently is where all my expertise comes from. Thanks so much for putting them up as otherwise I wouldn't have had the cojones to get on with this. The internet is awesome.



Cut this mangled piece out at last. I have a plan for crafting a new one. Haven't got around to it yet.



I had a feeling this section was worse than it looked. My aggressive drilling and lack of a sharp spot weld bit caused be to burst through outer panel. That didn't matter because the bog on the outer side revealed... well, it could be a baked bean tin repair...



So, off with the whole right rear hardtop. Ohhh...more unseen rust...



Cut, weld, grind...







Paint it before the outer bit gets curled over the top.



And now for this major...



This is a few weeks down the line now, and I've heard of the theory of metal shrinking lol. Adapted a cheap set of vice grips and off we go...



Nearly there...



It fits! Though, forgot to take pic of evidence.



And I must have thought it was satisfying to look at all the bits of rusty mess I'd cut off and replaced so far, so I took a pic of them ha ha...

 

[Flit]

Inside right rear lower, I see another large section needing repair. I also see the rear sill will need repairing too. That is a major, but I have a plan.



Cut cut cut, revealing about a cm deep of bog. And, I don't know if you can see it, but there is a massive layered dodgy repair there. Obviously what all this bog was hiding.



I will have to make a piece like this...



But I've run out of 18 gauge sheet, well at least not a piece this big at the moment, so back to small bits.

The ghastly bit I cut out:



The top section is fine...







Just as I started welding it in, CO2 ran out and left me with a couple of porous tacks.



That is progress so far. Will update when I can; if anyone seems interested that is.

 

[fuff66uk]

You are making a great job of it buddy,keep up the good work and keep updating us

 

[mm289]

Looking very good, I would be well please with the curved panels you are making up

MM

 

[Highway_Star]

Excellent work chap!

I'll be cheeky though and say it's not that rusty, you should see the state of a 1984 Landie or Land Cruiser over here

 

[wotwot]

Nice job and keep it updated it gives some of us inspiration to get on with our little projects.
And I agree not to rusty,on my 78 vw camper in places its difficult to tell where the rusts starts and the metal finishes lol .Think it was stored in a swimming pool !!!.

 

[octo0072000]

you are making a great job of it keep up the good work and keep updating us
and you think thats bad you want to see some discos land cruisers over home britain salts the roads

here is a linkj to 5 threads all about rusty discos have fun keep the pictures coming
this is a good one with pictures
http://www.landyzone.co.uk/lz/f8/discovery-sill-replacement-103369.html

and this one lots of pictures
http://forum.difflock.com/viewtopic.php?t=12757

http://forum.difflock.com/viewtopic.php?p=118700&highlight=#118700

 

[Flit]

Hi. I hope you all enjoyed the end of year celebrations.

Been a while since my last post. I really wanted to limit my posting here to clear progress. For a while it has seemed there has been just deeper digging into a mess. I'm pretty sure I have got to the bottom of the hole now and will have no more nasty surprises.

I managed to shape a replacement right rear guard section:

Though soon realised it would be beneficial to hold back on attaching that while I had easier access to some troublesome areas I was aware I needed to sort out. Starting to cut out the rear sill:

And here it is ...dead on the floor.

Replacement sill was more than I could afford. A bit of 18g sheet metal and a few folds at the local steel fabricators cost less than $80. It did cost a lot of my time.

I ruined a bit somewhere here and had to do half of it again. I realise I don't have a pic of it as it is now 95% finished.

Off with the spring:

...So I can get to this diagonal chassis bit, which is knackered. There it is, dead in the insert. Will have to make/get made this bit X2 sometime soon.

Tray floor has horrible rust here - photo doesn't do it justice. Cut.

Weld.

Other side. You may notice the chassis is a bit cleaner. Scraped all the anti noise crud off it. Scraped loads of dirt out of the middle of it. Blasted all the remnants of dirt out of the middle. Welded up many random useless holes. Finally a lick of paint to right rear. Rest to be done later. I think I must have cleared out about 5kg of dirt, rocks, pine needles from this side of it.

A bit of primer:

Cleaned up the arch. Filled holes and hammered out a few dents:

Today, I welded on this bit.

Still a bit of work to do on right rear ...before I can start on the other 3 corners. Getting there though, albeit slowly.

 

[vpug]

Hi
Very nice keep up the good work and you will be driving it by summer.


Thanks Vpug

 

[bill_gj]

And again - excellent stuff.