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Type: Posts; User: Nhoward

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    Roof bonding complete!

    Got some more done on the patrol...

    Dragged this thing out of the depths of my storage are:
    84430

    Did the flux/bronze/fire thing and brazed the corners on:
    84431

    Dressed the brazing and...
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    Major progress

    Managed to get a whole lot done since the last update...

    Fabricated this bit for the front left:
    84399

    Welded in:
    84400

    Fabricated this bit for the rear left and welded it in:
    84401
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    Still here and still at it...

    Well... MudRunnerTD called it - the tent got trashed.
    A couple of months ago we had the worst storm of the year, and at about 4am the top of the tent took off into the night. I was up to my...
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    Bit of an update

    Unfortunately I have been rather busy with work/life in general so progress has been a bit slow (and there is a subdivision going in next door, with construction 6 days a week, so I am trying to not...
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    Quick update...

    Got a bit more done...

    Clamped up the rear gutter section:
    83038

    Plug welded it in:
    83039

    Started on the first side piece...
    Apply a bunch of clamps:
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    You might be lucky and it is just surface rust,...

    You might be lucky and it is just surface rust, but if you can poke a screwdriver through it I'm afraid it has rusted from the inside out.
    You'll have to pull the headliner and have a look in the...
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    An update...

    I know it's been several months since I have updated this thread, but the project is still ongoing.

    So... what have I been up to?


    Welded up a ton of rivet holes on the sheet of steel that...
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    Passenger side reguttered

    Got the passenger side finished off.

    Started with this:
    82093

    Cut out some steel sections
    82086

    Persuaded them into the shape I wanted with this contraption (yes, that's a sheet metal...
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    On to the other side...

    Had the first weekend with good weather in a while so I got the tools out and pressed on with the patrol repairs...

    Started drilling out many spot welds holding the rusty gutter on:
    81880
    ...
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    I'll mention the photo makes it obvious why these...

    I'll mention the photo makes it obvious why these vehicles rust from the inside out.

    the roof is attached to the top of the gutter, leaving a void between the roof skin and the roof frame for...
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    Roof frame support fixup

    Got a bit more done on this project.
    Unfortunately I was rushing against an incoming storm so I did not take too many photos.

    Mark out some steel that will become the end of the roof frame...
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    Driver's side gutter time

    Managed to get the driver's side gutter completed and on the truck.

    Fabricate the last piece that fits at the front:
    81639

    Weld it on the bit I made earlier, grind it back and paint it:
    81640...
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    More cutting and welding...

    Got this weirdly shaped rusty area on the right rear corner to sort out:
    81572

    Made up a patch using a paper template:
    81573

    Tacked in place:
    81574

    Welded in:
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    Some overdue progress...

    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...
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    Time to do something about the rear right corner...

    Time to do something about the rear right corner of this thing...

    Welded in some temporary support struts:
    81082

    Removed the rusted bit of the existing support, removed the remains of the...
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    Some more progress...

    Finished welding in and grinding back a patch:
    81066

    Complete with some primer:
    81067

    Marked out some steel:
    81068

    Then chopped it up:
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    Yup... I work in IT so I am able to work from...

    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...
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    Right... time to something about that hole... ...

    Right... time to something about that hole...

    Use some paper to make a template, then trace the result on to some steel:
    81036

    Cut it out, stuck it in a bender then bash it with a hammer (or...
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    A short update...

    between the covid lockdown and a few weeks of bad weather I have not managed to get too much done, but I have made some progress;

    Chopped out a big chunk around the B-pillar:
    81021

    cut out and...
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    A little more progress

    I'm trying to be nice to the neighbors during lockdown, so I have not been working on the Patrol much.
    I have made a bit of progress though;

    A couple of patches coated in weld-thru primer drying...
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    slowly slowly...

    Got some more done:

    Cleaned up this bit where the frame had rusted out:
    80708

    Chopped a rusty bit out of the B-Pillar:
    80709

    measured up and chopped off a piece of server panel that had a...
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    Q&A

    Figured I would answer some of the questions you guys are asking...

    I left the seats in because they are already rather tired/stained/ratty so I'm not worried about the odd burn mark (and I don't...
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    a little progress...

    Got a bit more done today. Nice to be putting metal back into the patrol for a change.

    Cut out, bend up and prime some sheet metal:
    80667

    Clamp it in place:
    80668

    Tack it in:
    80669
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    Some progress...

    Made some progress on the patrol over the weekend.

    Out came the air saw, and off came large chunks of bodywork:
    80590

    80591

    The Headliner support brackets were removed, more rusty bits...
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    I toyed with the idea of swapping the shell or...

    I toyed with the idea of swapping the shell or grafting on a donor roof, but I have very little chance of finding either in good condition over here in NZ. Our humid climate and day/night temperature...
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