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Old 01-27-2007, 08:37 PM
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Default Metalworking Advice Needed

Working on getting everything "just right" before I weld up the B-pillars on my 76 FJ40 resto project, I decided to take few measurements off my 71 FJ40, and boy am I glad I did. To recap, I am basically fabbing a new tub from scratch using CCOT panels to graft in to what's left of the 76. CCOT has you save the old lip portion of your old tub, because they are usually not too rotted (correct) and would be super hard and expensive to produce and sell.

Cut to the chase:

When I fitted the old lip up to the new B-pillars, they sorta fit the profile:
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Old 01-27-2007, 08:39 PM
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I noticed that at the rear, the CCOT rockers didn't quite line up, but I figured I could make a shim out of some sheet metal in an L shape and weld it in.
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Old 01-27-2007, 08:41 PM
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The inside front didn't fit perfect, but a quick pass with the angle grinder made quick work of that,
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Old 01-27-2007, 08:43 PM
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The following two photos show what the bigger picture looks like. The original, saved lip extends all the way from the A-pillar to the rear of the quarter panel where the ambulance door will hinge.
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Old 01-27-2007, 08:48 PM
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Tonight, I got out the tape measure to make sure everything was "just right" I was shocked to discover that the whole original B-Pillar needed to move rearward by 1/2" to match the 34.5" measurement of my 71 from the rear edge of the A-Pillar to the rear edge of the B-Pillar. I cut the CCOT rockers and then bent them back straight to figure out a new bend later, then positioned the original lip at the proper 34.5" location. (FWIW, I double checked the doors on the 71 and the 76, and they are same-same dimensions).

After much measuring and grinding away, I now have what you see in the following photos:
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Old 01-27-2007, 08:54 PM
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So, as you can see, the bend of the CCOT rockers is way too far forward to fit. My question is, what advice can I get on how to match the CCOT rocker edges at the B-Pillar to weld to the bottom of the original B-Pillar? Cut and substitute a new section? Heat and blacksmith? Bend gently with vice grips? Lotsa bondo? :-)

The photo below shows where I have marked with a sharpie pen where the bend in the rockers should approximately be.
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Old 01-27-2007, 11:03 PM
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Sorry, no help here Jeff. Matt Andersen (buckroseau) is a metal-working master on MUD, doing a LPB resto in the 45 section, you might try to PM him and see what he thinks. The guy seems to have a solution for everything!

If it were me, I'd probably cut the rocker and splice in a piece that shifts the rocker back to where it needs to be. That way you don't have to dork with the curve of the lip, and it's pretty much just a rectangular-shaped piece of metal you're putting in. But then again I've never worked with metal...
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Old 01-28-2007, 12:03 AM
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Quote:
Originally Posted by subzali View Post
If it were me, I'd probably cut the rocker and splice in a piece that shifts the rocker back to where it needs to be. That way you don't have to dork with the curve of the lip, and it's pretty much just a rectangular-shaped piece of metal you're putting in.
That'd work good if the rockers weren't already welded in GOOD to the floorpans. At this point dorking with the curved sections will be most practical.
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Old 01-28-2007, 09:16 AM
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I am having trouble following you jeff. Do you just need to remove the section you have outlined on the brown tub? Or to you want to bend it in? What?

It looks like you want to section that part out so the new will slide in there? Is that correct? That a tough bit oh business there, but if that's that you need to do, I would find a plasma cutter and torch it out. Oxy will over heat the area and warp the crap out of it.

I am sure there is someone on the west side who has a portable unit, I think I am too far away for ya.
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Old 01-28-2007, 12:11 PM
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Quote:
Originally Posted by green machine View Post
I am having trouble following you jeff. Do you just need to remove the section you have outlined on the brown tub? Or to you want to bend it in? What?
Correct, the mark shows where the profile of the rocker should be. I am trying to match the profile of the rocker panel (incorrect due to the bend occurring too far forward) with the profile of the lip (which is the original lip from the factory). The door won't close properly if I simply welded it in the way it is now. Basically the two main things I am thinking of are to either cut that section out, or to somehow re-bend it to the proper profile, which seems to me to be less likely to work.

Quote:
Originally Posted by green machine View Post
It looks like you want to section that part out so the new will slide in there? Is that correct?
Kinda sorta. If the replacement rocker panels had been bent properly to begin with, it wouldn't have been a problem. I am very happy, overall, with all the parts I've purchased from CCOT, and it's a given that the installer needs considerable skill to build a tub practically from scratch. They've been helpful over the phone and email. This particular problem really has me scratching my head on the best approach though. If the Heritage parts had been available when I was buying parts for this project I may have gone in that direction though.
Quote:
Originally Posted by green machine View Post
That a tough bit oh business there, but if that's that you need to do, I would find a plasma cutter and torch it out. Oxy will over heat the area and warp the crap out of it.
I don't have plasma, so my precision cutting is generally with a small, air powered cutoff wheel.
Quote:
Originally Posted by green machine View Post
I am sure there is someone on the west side who has a portable unit, I think I am too far away for ya.
Oh I can cut it out, and cut and bend a curved, crescent shaped piece to graft in. That's kind of the direction I'm leaning towards.

Thanks for posting up; you're among the folks in this club who has a LOT of experience with this sort of thing, and I really respect your advice!
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