Yup... I work in IT so I am able to work from home pretty easily. Combine that with a senior management team that are bored senseless as a result of the lockdown, and it's very easy to get buried in more work than you would have otherwise.
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Finished welding in and grinding back a patch:
Attachment 81066
Complete with some primer:
Attachment 81067
Marked out some steel:
Attachment 81068
Then chopped it up:
Attachment 81069
I did three of these in total, then ran them through the bender and welded them end to end.
The end result is too long to easily take a photo of, but it should be welded to the side of the frame rail in due course.
Cleaned up the rear of the thing - removed what remained of the rear gutter and marked out the bit I need to cut out and patch:
Attachment 81072
I ground off the rust in the good areas and gave them a shot of primer, but it was too dark to get a good photo.
The next task is the back corner. A bit rusty...
Attachment 81071
I'll have to fabricate and weld in a temporary support for the roof frame before I chop that lot out.
You are amazing, brilliant work, top stuff
Time to do something about the rear right corner of this thing...
Welded in some temporary support struts:
Attachment 81082
Removed the rusted bit of the existing support, removed the remains of the gutter and marked out the intended path of the body saw:
Attachment 81083
Marked out the cut on the rear:
Attachment 81084
A few moments with the body saw... no more rust, but some big holes to patch:
Attachment 81085
Attachment 81086
Test fitted the gutter I fabricated earlier:
Attachment 81087
Needs to be another 250mm longer, but looks like it'll work.
How is your project coming along ? would love to see some more updates.I have just started doing this to my "92 GQ patrol" not as bad as yours, but still needs doing....and your pics,ideas etc are excellent.I see you are in NZ as I am,where abouts ?? Anyway thanks for your project updates,would love to see some more....cheers
Unfortunately life and Auckland weather have been getting in the way as of late, but I have managed to get a bit more done:
Time to do something about this oddly shaped hole where the A-Pillar connects to the roof frame...
Attachment 81549
Cut up some patch plates and give them a shot of weld-thru:
Attachment 81550
Do a bunch of fiddly welding to rebuild the edge piece:
Attachment 81551
Weld in the first part of the patch (had to call it a day at this point so I just fired some primer over it):
Attachment 81552
Picking up where I left off, grind back the primer etc. and get ready for more patching:
Attachment 81553
In with the next patch. This area has a join between panels, so I replicated that with my repair (overlap & plug welds):
Attachment 81554
Weld everything up:
Attachment 81555
Apply the finger sander, angle grinder and die grinder:
Attachment 81556
Hide all that with some primer:
Attachment 81557
That's all the rust in the driver's door are repaired, on to the rear end.
Tack in the patches:
Attachment 81558
Attachment 81559
Some more welding...
Attachment 81560
Add some primer:
Attachment 81561
Just need to finish off the back right corner, then the drivers side frame repairs will be complete.
Got this weirdly shaped rusty area on the right rear corner to sort out:
Attachment 81572
Made up a patch using a paper template:
Attachment 81573
Tacked in place:
Attachment 81574
Welded in:
Attachment 81575
Hit with the grindy tools:
Attachment 81576
Quick squirt of weld-thr:
Attachment 81577
Now for this one... As it was originally where two panels overlap and join, this was a little more complicated.
Attachment 81578
Weld in the first patch:
Attachment 81579
Grind it flush:
Attachment 81580
Stick the second patch over the top:
Attachment 81581
Weld it in:
Attachment 81582
Grind it back:
Attachment 81583
Apply paint:
Attachment 81584
With this bit done, I can now say that the driver's side roof frame is rust free!
Next is to fabricate and weld on a new gutter, then do something about the roof support framework that is currently hanging mid-air.
Managed to get the driver's side gutter completed and on the truck.
Fabricate the last piece that fits at the front:
Attachment 81639
Weld it on the bit I made earlier, grind it back and paint it:
Attachment 81640
Spend quite a long time doing many, many plug welds:
Attachment 81641
Almost there (welding up the front at this point)
Attachment 81642
Gutter attached:
Attachment 81643
I admire your skills and patience :clapping:
Looking good.