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21st August 2020, 09:50 AM
#31
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 support...
steel-origami.jpg
Use a combination of a sheet metal bender and some hammers to fold it up
folded-up.jpg
All three bits welded in and primed - the roof frame is no longer hanging in mid-air.
welded-in.jpg
With that, the driver's side is done! Now to do the same process on the other side...
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The Following 7 Users Say Thank You to Nhoward For This Useful Post:
0-TJ-0 (21st August 2020), Lawrence (26th September 2020), MB (22nd August 2020), mudnut (21st August 2020), MudRunnerTD (22nd February 2021), Rossco (21st August 2020), Sherro (23rd August 2020)
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21st August 2020 09:50 AM
# ADS
Circuit advertisement
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21st August 2020, 02:15 PM
#32
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 moisture to accumulate.
The rust proofing in this area also appears to be sub optimal - paint does not seem to make it down in to the void during manufacture, so we are just left with the phosphate coating to protect the underlying steel.
My current theory on the corrosion is condensation forms on the inside of the roof, runs down the inside and pools in the void, with nowhere to go.
In order to prevent the roof rusting out again any time soon, I am planning to insulate the inside of the roof skin with dynamat or similar, inject something like two-pack stone chip paint into the void between the frame and the roof skin, and drill some drainage holes in the gutter so that any moisture that accumulates has somewhere to escape.
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The Following 7 Users Say Thank You to Nhoward For This Useful Post:
Cremulator (21st August 2020), jack (21st August 2020), Lawrence (26th September 2020), MB (22nd August 2020), mudnut (21st August 2020), MudRunnerTD (22nd February 2021), Rossco (21st August 2020)
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21st August 2020, 09:52 PM
#33
Patrol Guru
Always happy when I see your thread pop up with a new update. Satisfying watching it come together mate, good job.
2003 GU TD42 with a few extra ponies
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29th August 2020, 06:15 PM
#34
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:
rusty-gutter.jpg
Started chopping some of the gutter out:
begin-gutterectomy.jpg
Welded in some temporary supports for the roof frame, marked the ends of the roof frame that need to go, and started cutting:
marked-and-cutting.jpg
Stripped off the rusted mess that was once the passenger side gutter:
gutter-gone.jpg
Hauled out the old oxy-acetalyne rig and used that to get the old braze off the corners.
Kind of scary holding the torch in one hand and the drill with the wire wheel in the other, and playing "dodge the flying molten metal" but it came up well:
braze-removed.jpg
Went at what remained with the wire wheel, the stripping disk and the sanders:
derusted.jpg
After that was done I gave the area a wipe down with some rust converter to catch anything I missed with the power tools and called it a day.
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The Following 6 Users Say Thank You to Nhoward For This Useful Post:
jack (29th August 2020), MB (30th August 2020), mudnut (29th August 2020), PeeBee (29th August 2020), Rossco (29th August 2020), Wine_maker (3rd September 2020)
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25th September 2020, 01:33 PM
#35
Passenger side reguttered
Got the passenger side finished off.
Started with this:
side_primed.jpg
Cut out some steel sections
steel-chunks.jpg
Persuaded them into the shape I wanted with this contraption (yes, that's a sheet metal folder clamped to my kitchen bench):
kitchen-bending.jpg
Ended up with three of these:
rail-sectiopns.jpg
Welded them end to end and test fitted:
test-fit.jpg
Finished it off, drilled a bunch of holes and clamped it to the truck>
clamp-on.jpg
Spent far too long making far too many plug welds:
many-many-many-plugwelds.jpg
All welded up:
gutter-welded.jpg
Welded on some new roof frame support brackets I bent up, ground back all the welds and gave it a shot of rustkill paint:
painted.jpg
Now I have to sort out the not insubstantial rust in the roof support frame, then it's on to the roof skin itself.
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The Following 4 Users Say Thank You to Nhoward For This Useful Post:
0-TJ-0 (25th September 2020), jack (25th September 2020), mudnut (26th September 2020), Plasnart (25th September 2020)
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22nd February 2021, 07:18 PM
#36
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 used to be over the sunroof:
well-rivet-holes.jpg
Flipped the roof over:
inside-root.jpg
Started tacking:
mega-tackjob.jpg
Back over it goes to begin a very long, slow stitch welding job:
start-stitch-welding.jpg
Gave it a whack of etch primer:
welded-primed.jpg
Chopped all this rusty junk off the edges:
edges-off.jpg
Ground off the last of the rust in the roof support frame:
rust-begone.jpg
Last patch going in to the roof support frame:
last-patches.jpg
All coated in rustkill paint:
roof-subframe-done.jpg
blackification.jpg
Started building this support to bridge the gap and reinforce the roof frame where the sunroof used to mount:
new-support.jpg
finishing-support.jpg
Plug welded both ends in:
plugwelded.jpg
Gave it the usual rustkill treatment:
painted-black.jpg
Left it to dry for a few hours, then dropped the roof on top:
roof-on.jpg
roof-on-inside.jpg
Next is the fun task of welding in strips on all sides to fill the air gap, then plug welding them to the gutters.
Also found this mess lurking under a tin's worth of filler:
new-mess.jpg
Should be straightforward after what I've done so far.
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The Following 7 Users Say Thank You to Nhoward For This Useful Post:
0-TJ-0 (22nd February 2021), Cremulator (23rd February 2021), jack (22nd February 2021), MB (23rd February 2021), mudnut (22nd February 2021), MudRunnerTD (22nd February 2021), Rossco (22nd February 2021)
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22nd February 2021, 07:29 PM
#37
Was wondering where you have been? Great job, loving this build. Brilliant documentary also. thanks
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22nd February 2021, 08:56 PM
#38
Breadmaker Shaker
Great to see you back NH. This is such a great thread, love your work mate! Can't get enough of skilled panel work and so well presented.
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22nd February 2021, 10:12 PM
#39
Moderator
Looking great mate. I too rebuilt a GQ in the back yard and used one of those White Tents. it got it done but loving a Shed now. I had the tent set up and the car fully prepped for paint. masked up and rubbed back, washed down with wax and grease remover and ready to go...... Got up at 7am the next morning for Paint and it was blowing a bloody gail from over the side fence and it got up and under the tent and destroyed it.... On Paint Day! Hours and Days of prep was gone. Was a very shit day. i was gutted. i could just sit and look at it.
Your project s coming up a treat mate. a Credit to you.
Its a Nissan! =====> Its a Keeper!! ....... Got a TD42 in it BONUS!!
....... I'm a lucky bugger! I've got 2 of em!
Check out my Toy -->
MudRunnerTD's GQ From the Ground Up
Originally Posted by
Rogue Dung Beetle
Wish it was Nissan though, Toyotas just can't keep up with the Pootrol pace.
The only good thing about an 80 series is..... the front end?? Wrong!!, the Engine?? Wrong!! the Full Time 4WD system?? Wrong!! Its the NissanPatrol.com.au stubby holder fitted over the transfer lever.
WARNING: Towballs used for recoveries can, and do kill people and damage property.
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The Following 2 Users Say Thank You to MudRunnerTD For This Useful Post:
MB (23rd February 2021), Rossco (23rd February 2021)
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11th March 2021, 02:38 PM
#40
I just bought a 1980 MQ that has what appears to be a couple small rust sections in the roof at the gutter line (as well as the door corners but that should be easy). I was thinking an easy fix, but after seeing what happened to this one I am dreeding to see what lurks behind. I can only hope that it is not as bad as that
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The Following 4 Users Say Thank You to Intrinsic For This Useful Post:
MB (25th March 2021), PeeBee (11th March 2021), Plasnart (25th March 2021), Rossco (11th March 2021)