Reed 78 FJ40 Rebuild

[reaper71]

Hey guys, back again with another project for a customer.
This is something I have been working on for a little while (turned out to be more work than we thought!!!)
It is a 1978 Toyota FJ40 the plan is rebuild the body and tub,lift the suspension install a 383 small block and build a roll cage.


When the body was brought to me it was in VERY poor condition.
Rot everywhere you looked it was sandblasted underneath to remove the old nasty stuff before it was dropped off.
It will receive new Quarter panels, new Rocker panels, floor panels as needed ,bracing and any other spots as needed.

Mark...

[reaper71]

Pic #1. This was taken after I had mocked up the new Quarter panel and started cutting things off. (sorry do not have a before shot)

Pic #2. The new Quarter panel.

Pic #3. I changed gears here real quick so I could get the new Rockers installed so this is of the inner structure being rebuilt.

Pic #4. After it was all redone and ready to fit the new rocker.

Mark...

[RockinKees]

I'll follow along Mark.
I really like the way you tackle things, I can learn so much from you!

This Toyota is (was) a Jeep lookalike, right?

[tune_1]

Glad you are posting this new project, will be fun to see.

Dwight

[reaper71]

Kees, Yes they are very similar in the look of them (I feel they are better looking than the jeep)
Thank you my friend for checking this out it has been a fun project!
We ALL can learn from one another!

Mark...

[reaper71]

Thank's Dwight!
More to come..

Mark...

[reaper71]

I want to apologize for the lack of BEFORE shot's !!
I thought I took several but I didn't so this is what I had..

Pic #1. The new rocker being fit.

Pic #2. After I got it tacked in place.

Pic #3. All welded and metal finished.

Pic #4. The Drivers side.

How I fit the new rockers, I first started with the passenger side panel (new) flipped it over and layed it over the top of the (old) drivers side and traced the shape and repeated for the passenger side. This gave me a perfect cut line on both sides.

Mark...

[reaper71]

Pic #1. The Drivers side all wrapped up.

Pic #2. This is a shot of the passenger side wheel tub "parts" as they were removed to be replaced.

Pic #3. The tub after the pieces were removed.
The reason it was done this way is do to things wanting to flex the rear section of the floor was rotted and if I were to remove the entire tub things would get out of hand. Besides the rest of the tub was decent shape.

Pic #4. The new panel being fit.

Mark...

[RockinKees]

I just was going to ask why not replace the whole wheeltub, but you was a bit quicker then me and answered it at #3

Seems a lot more work thou?

[reaper71]

HaHa! yes after I looked over things, before I started to cut things out I noticed that the floor and the sides would move to much so I had to go this route. It is more work in some ways (I did check on new tubs they were $600 ea!! ) so the customer said to just fix the bad spots!

Mark...

[reaper71]

Pic #1. Tacking it all in place.
I did spray rust encapsulator on the supports before I tacked this in.

Pic #2. After all the welding and metal finish was done.

Pic #3. In this shot I'm showing the new flange being made. The entire flange when done will have holes popped in it for spot welds for the quarter panel.

Pic #4. After metal finish was done. (And you can see how bad the rear sill was rotted and needed to be replaced before the quarters go on)

[reaper71]

Pic #1. Here I've started on the front section of the tub. There is a few different angles to make for this piece. also if you notice the floor section will need repair work as well.

Pic #2. Another shot of the floor section. This area has an under structure of the support that is flanged, the floor section that is flanged and the panel for the tub is also flanged. They will all be spot welded together like the factory.

Pic #3. The new floor piece being fit.

Pic #4. all welded and metal finished.

Pic #5. The new panel for the tub ready to go in.

Mark...

[Advanced Design]

Nice work Mark. Boy, this is sure one where you have to think about sequence of repairs...like you did with the tub. Good example for all of us to follow.

Wow, that is rusty. Are these vehicles pretty rare?

[reaper71]

Thank's again Doug!
It was one of those thing's where you sit,study and finally Do..
The odd thing is, they are not super rare but they have a HUGE following for these things and bring Stupid money for them Restored!
A company by the name Icon does a ground up build and are getting $125,000.00 for them!! Fuel inj. Kevlar coating for the body etc.

Mark...

[reaper71]

Pic #1. The panel welded in.

Pic #2. The flange spot welded like factory.

Pic #3. This is the old sill (under the rear doors) This will need to be replaced before I can move forward with the quarter panel. (it was on order as well as the side uprights that's why I started on the tub first)

Pic #4. The rotted floor section removed. (if you notice the aluminum angle holding the sides together to keep from moving)

Pic #5. This was the new floor panel installed. If you look close the passenger side upright is rotted and will be replaced as well (was on order as mentioned above)

Mark...

[RockinKees]

Boy, that's some repair work!
I'm glad you know what you are doing!!

[reaper71]

LMAO!! yeah,well I'm figuring things out as I go Kees!!

[reaper71]

Pic #1. Sill being fit, checking for being square for the door opening etc.

Pic #2. All spot welded in place. Now ready to start with the quarter panel.

Pic #3. The flange has been punched with holes for spot welding.


Pic #4. Fitting the QTR.

Pic #5. All tacked and spot welded.

Mark...

[alsriv2]

1st class metal working skills you have there. Great job on the restore of this Toyota!

[reaper71]

Thank you very much!

[Advanced Design]

Wow, extensive repair. Nice work. Is there a rolled edge along the bottom of the quarter and wheel opening?

[reaper71]

Yes! Just like factory they are really nice quality pieces.


Mark...

[reaper71]

Pic #1. Here I'm showing the back section after it was welded to the sill, and ready for A Lot of welding..

Pic #2. After the welding,Grinding and metal finish was done.
I textured the metal for the Armorthane coating that was going to be applied originally but the customer has since changed his mind and is going with the Kevlar coating instead.

Pic #3.In this pic it shows the old QTR cut off (the black line shows the actual cut line and if you notice there is the old metal from flange still attached)

Pic #4. This was taken to shoe the old brace that will need some repair!

Mark...

[reaper71]

Pic #1. The upright was replaced and the first panel replaced in the rear section tying the floor and upright together. (The reason I went this route is I did not want to cut to much off and have things get out of hand)

Pic #2. Support brace was repaired,drilled and new flange nuts installed (SAE Nuts) Then the new patch welded in.

Pic #3. Her I am starting to make the new flange.

Pic #4. In this shot I am using 1x1 tube clamped to the tub to keep it nice and straight while welding. And if you notice the remaining portion of the tub has been repaired. These spots (with holes) are for the future RollCage to be bolted to.

[RockinKees]

Man!
You're building a complete new Toyota!!
Really nice work Mark!