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  #21  
Old 01-28-2009, 09:04 PM
zornff zornff is offline
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I'd cut the back half off and make an fj45 pu. Oh wait, thats just me . Keep up the good work, and get ALL the rust out.
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  #22  
Old 02-08-2009, 08:11 PM
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Default slow progress...

It's not that a project like this takes weeks and weeks of effort, except when you only get a couple hours here and a few hours there to work on it. Plus I got derailed with a leaky brake master cylinder, which I replaced with a new OEM unit and bled the system. Brakes are in good shape....

4 new OEM body mounts (coutesy of Jerry at BT).



The body mounts should have been easy, but I wrestled with them for a few hours given the limited space to work in back there. You need to have midget hands to do this job well.

Here's what she looks like now with the new CCOT channel mounted (the black piece) you see extending into the quarter panels. The complete kit from CCOT includes a new piece of sheet metal (the white primed piece), which needs to be welded on.



So now I need to cut new sheet metal for the fenders, and fill in a few gaps in other areas to finish this up. Since I don't have a welder at the moment, this last step could take a while....
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  #23  
Old 02-08-2009, 08:25 PM
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Talk about deja vu batman! That white piece is what I was working on today, on my 76. I had trimmed the ends to fit last weekend, but went to get it ready for welding today. I had to dork around with the two inside body mounts to get it in there. I kind of moved them out of the way, I don't want to melt them when I go to weld it in later this evening. Yours is obviously a later version. When I bought mine, they hadn't been drilling holes in the back to weld through, and I ended up drilling my own. I drilled two rows, I see they have one.
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  #24  
Old 02-08-2009, 10:34 PM
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Quote:
Originally Posted by Jacket View Post
So now I need to cut new sheet metal for the fenders, and fill in a few gaps in other areas to finish this up. Since I don't have a welder at the moment, this last step could take a while....
Looks like a new exhaust system is somewhere on the list, too.
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  #25  
Old 02-09-2009, 07:43 AM
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Quote:
Originally Posted by Shark Bait View Post
Looks like a new exhaust system is somewhere on the list, too.
Indeed! That courtesy of the BOWAGW run last summer. It cracked in about 10 places that afternoon..... The backfiring in the mall parking lot can be fun though.
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  #26  
Old 02-09-2009, 08:03 AM
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Looking good Matt. What are you going to use to replace the cut portions of fender? Are you going to bend flat sheet metal, or did you purchase some of the patch panels from CCOT?

What kind of welder have you picked out??
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  #27  
Old 02-09-2009, 08:59 AM
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Plan A is to bend some flat sheet - I've got a small sheet of 16g cold-rolled that I'll begin experimenting with some time soon.

Welder - leaning toward a Lincoln pro-mig 180. I've got a couple of leads for a decent deal....

If all goes well, a replacement front bumper for the log I currently have attached will be next. Some good inspiration out there from Rezarf and Zepp.
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  #28  
Old 02-09-2009, 11:57 PM
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Matt- You are welcome to my welder if you want to play around with it before you buy one. Mine is a Lincoln 175spt... or in other words, the old version of the one you are looking at.

I'd love to practice on YOUR cruiser first... you know, get all the bugs out
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  #29  
Old 04-05-2009, 08:44 AM
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The new channel wings didn't line up perfectly, and I had to grind a bit off the passenger side and do some creative tacking to get everything to line up as good as possible.

For the new fender pieces, I traced the existing cutout onto a piece of paper, then traced that onto cardboard, and then finally onto the sheet metal. I got pretty close with the cuts, but tried to error on the side of too big whenever necessary.



The 16g bends pretty easily with some clamps, and I tried to start at one end and work my way to the other. To try and control the heat and warping, I just did a series of tacks all along the seam, starting with 2" (or more) gaps, then filling in the spaces. I drilled holes in the custom pieces, and tried rosette welds through to the channel wings.

Driver's side in the middle of tacking it in. I had a bit of trouble getting good welds without burning through.


Passenger side tacked in. Welding got better on this side.



And welds ground down



Next up I'm going to fill in the remaining holes with Duraglass and seam sealer, then cover it with some filler.
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  #30  
Old 04-05-2009, 08:47 AM
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An FJ40 drive shaft is the perfect radius to bend those panels...
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