Sunday, September 16, 2012

September 16, 2012 FJ40 Restoration Update

After lots of delays and preparation I finally had a full day of stripping Dubbeltjie.

One of the challenges was rusted bolts - I broke a few and am going to have to get them out using a tap-and-die set.  I used a product called PB Blaster, which is amazing.  I think with a little more patience I would not have broken as many bolts.  Spray any rusted bolt with PB Blaster, let it soak to work its magic for a short while and then slowly work the bolt out.  Sometimes - for really bad rusted bolts - I would let it soak overnight and then try it again the next day.  At times I would also work the bolt back and forth and spray a little more PB Blaster, soak and then gradually work it some more.

These bolts were tough to remove.

When I removed the glass at the back part of Dubbeltjie I didn't cracked any of the panes - however, the windshield was a different story.  Cracked it at first try - must have been aftermarket glass and not the sturdy Toyota glass.

Buggered up the glass

This is some sort of heat/sound barrier which I discovered under the rubber floor mats

Progress





Sunday, September 9, 2012

Dubbeltjie, FJ40 Restoration Project Update

This weekend I started taking Dubbeltjie apart.  This process uncovered a number of good things - like places with no rust - and a number of bad things like areas with more rust than I expected.  My concerns of what lurks under the Rhino Liner remains to be discovered.  Check out the "take down" of the rear doors, front doors, rear body and rood.

Removed the rear & front doors
Duppeltjie without doors.  I also removed the windows - the trick is to make sure the rubber molding holding the window is warm and pliable.  Work one corner from the inside out - make sure to put a soft carpet or blanket on the floor to break the glass when it falls.  After working the molding and lots of pushing, the windows came loose and popped right out. 

Removed the roof but in the process broke a bunch of bolts.  Discovered a lot of rust in the roof drip-rail.  I will need to replace it and rebuild this part of the roof.

Broken bolts :(

No rust! But a broken bolt.

Slowly coming apart...

Roof where I pulled back the black roof0liner.

Topless

Rust
More rust