Finished welding in and grinding back a patch:
groundback.jpg
Complete with some primer:
patchpainte.jpg
Marked out some steel:
markup.jpg
Then chopped it up:
chopped.jpg
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:
rrrust.jpg
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...
rrcorner.jpg
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:
temporarysupports.jpg
Removed the rusted bit of the existing support, removed the remains of the gutter and marked out the intended path of the body saw:
gutterectomy.jpg
Marked out the cut on the rear:
problem-circled.jpg
A few moments with the body saw... no more rust, but some big holes to patch:
rear-rustectomy.jpg
side-rustectomy.jpg
Test fitted the gutter I fabricated earlier:
gutter-testfit.jpg
Needs to be another 250mm longer, but looks like it'll work.
0-TJ-0 (18th May 2020), Cremulator (9th July 2020), mudnut (18th May 2020), MudRunnerTD (22nd February 2021), oxmann (9th July 2020), Rossco (17th May 2020)
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...
dificult-hole.jpg
Cut up some patch plates and give them a shot of weld-thru:
primed-patches.jpg
Do a bunch of fiddly welding to rebuild the edge piece:
edge-rebuilt.jpg
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):
half-patched.jpg
Picking up where I left off, grind back the primer etc. and get ready for more patching:
hole-prepped.jpg
In with the next patch. This area has a join between panels, so I replicated that with my repair (overlap & plug welds):
patch-tacked-in.jpg
Weld everything up:
welded-up.jpg
Apply the finger sander, angle grinder and die grinder:
apply-grinder.jpg
Hide all that with some primer:
hide-sins.jpg
That's all the rust in the driver's door are repaired, on to the rear end.
Tack in the patches:
patch-tacked.jpg
rear-tacked.jpg
Some more welding...
rear-welded.jpg
Add some primer:
rear-painted.jpg
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:
rusty-corner.jpg
Made up a patch using a paper template:
tricky-patch.jpg
Tacked in place:
tricky-patch-tacked.jpg
Welded in:
tricky-patch-welded.jpg
Hit with the grindy tools:
corner-grindback.jpg
Quick squirt of weld-thr:
corner-painted.jpg
Now for this one... As it was originally where two panels overlap and join, this was a little more complicated.
rear-hole.jpg
Weld in the first patch:
patch1-welded.jpg
Grind it flush:
patch1-ground.jpg
Stick the second patch over the top:
patch2-tacked.jpg
Weld it in:
patch2-welded.jpg
Grind it back:
patch2-groundback.jpg
Apply paint:
rear-painted.jpg
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:
rail-end.jpg
Weld it on the bit I made earlier, grind it back and paint it:
rail-painted.jpg
Spend quite a long time doing many, many plug welds:
bulk-plugwelds.jpg
Almost there (welding up the front at this point)
almost-there.jpg
Gutter attached:
complete.jpg
0-TJ-0 (8th August 2020), BrazilianY60 (31st May 2021), Cremulator (6th August 2020), MB (6th August 2020), MudRunnerTD (22nd February 2021), Plasnart (6th August 2020), Rossco (21st August 2020), TimE (6th August 2020)
I admire your skills and patience
Time Marches On .....and on ..... and on
Looking good.