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Old 04-26-2006, 03:29 PM
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Rzeppa Rzeppa is offline
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Default Last Minute Project

Every year, it seems I have some kind of last-minute wrenching project before Moab. This year, I vowed to fix the rusted rear sill. Ian had given me a section of 2x2 square tube at the packing party a couple years ago, and last year at Moab, Bob Brown, who was following me on a trail, noted that every time I went over a bump, he could see air between the rear of my body and the frame crossmember.

Here's what I had to start with:
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Jeff Zepp
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1971 & 1976 FJ40s, 1978 FJ45, 1987 FJ60
Rising Sun 4WD Club, TLCA #4063
http://american3dprinting.net/

Last edited by Rzeppa; 04-27-2006 at 11:06 PM.
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Old 04-26-2006, 03:31 PM
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First I measured and drilled holes for the body mounts in the square tube:
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Jeff Zepp
Kittredge CO USA
1971 & 1976 FJ40s, 1978 FJ45, 1987 FJ60
Rising Sun 4WD Club, TLCA #4063
http://american3dprinting.net/

Last edited by Rzeppa; 04-27-2006 at 06:52 PM.
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Old 04-26-2006, 03:33 PM
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I had to fit the body mounts through the back of the square tube somehow, so I cut some openings:
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Jeff Zepp
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1971 & 1976 FJ40s, 1978 FJ45, 1987 FJ60
Rising Sun 4WD Club, TLCA #4063
http://american3dprinting.net/
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Old 04-26-2006, 03:36 PM
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Cutting out the old sill. As you'd imagine, the body mount bolts just twisted off, even after soaking with liquid wrench. What the hey, I got new ones! You can see the condition of the old sill - it's history!
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Jeff Zepp
Kittredge CO USA
1971 & 1976 FJ40s, 1978 FJ45, 1987 FJ60
Rising Sun 4WD Club, TLCA #4063
http://american3dprinting.net/
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Old 04-26-2006, 03:39 PM
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After that, I posted up on the LCML, asking for advice on how to mount the spare carrier latch. I got a lot of good suggestions; in the end I cut openings through which I could install nuts and washers onto bolts. I was thinking of welding nuts in there, but wanted to make sure I had a little slop in order to position the latch just right. It was late, I was tired and this project was already taking WAY longer than I planned.

Due to parallax of the camera angle, it doesn't look like the cut-outs line up behind the holes. They actually do.
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Jeff Zepp
Kittredge CO USA
1971 & 1976 FJ40s, 1978 FJ45, 1987 FJ60
Rising Sun 4WD Club, TLCA #4063
http://american3dprinting.net/
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Old 04-26-2006, 03:41 PM
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Here's a couple other angles of the finished square tube:
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Jeff Zepp
Kittredge CO USA
1971 & 1976 FJ40s, 1978 FJ45, 1987 FJ60
Rising Sun 4WD Club, TLCA #4063
http://american3dprinting.net/
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Old 04-26-2006, 03:43 PM
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Next up was to cut the "wings" for the ends. I "cheated" and used my CCoT channel on my 76 as a template. Cutting 4 of them with reasonable precision took quite a while.
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Jeff Zepp
Kittredge CO USA
1971 & 1976 FJ40s, 1978 FJ45, 1987 FJ60
Rising Sun 4WD Club, TLCA #4063
http://american3dprinting.net/
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Old 04-26-2006, 03:45 PM
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After I had all 4 cut out, trimmed and ground, I welded them to the ends of the square tube:
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Jeff Zepp
Kittredge CO USA
1971 & 1976 FJ40s, 1978 FJ45, 1987 FJ60
Rising Sun 4WD Club, TLCA #4063
http://american3dprinting.net/
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Old 04-26-2006, 03:47 PM
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Next, I cut some rectangles for the curved outside, and welded them in:
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Jeff Zepp
Kittredge CO USA
1971 & 1976 FJ40s, 1978 FJ45, 1987 FJ60
Rising Sun 4WD Club, TLCA #4063
http://american3dprinting.net/
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  #10  
Old 04-26-2006, 03:48 PM
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Some poor-light photos of the whole thing:
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Jeff Zepp
Kittredge CO USA
1971 & 1976 FJ40s, 1978 FJ45, 1987 FJ60
Rising Sun 4WD Club, TLCA #4063
http://american3dprinting.net/
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