Ashes
Well-Known Member
So TJ I came home to find a spot weld cutter on the counter, what a fun present from my dad ha ha.
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Help Support Hardline Crawlers :
Doing Some Body Work! Tips?
- Thread starter 84Toyota4x4
- Start date
Nice! :corn: You know there's only one thing hotter than a girl who can weld, and that's one who can cut her truck apart and weld it back together. Make sure TJ doesn't take all the glory. :awesomework:
84Toyota4x4
Well-Known Member
Well, I got some pictures today. I had the day off so I drove home from Ft Lewis and spent a couple hours working on the 4Runner.
I got the last of the core support off today, straightened the inner fender on the drivers side some more, and got everything lined up pretty much right. I was impressed.
Here is a picture of the truck with the core support still on. It doesnt look that bad since I pried it back out straight to help with getting the radiator out, bumper off, etc.
And heres a couple pictures of the "bent frame". Mine measures exactly 27 1/4" from the inside of the frame channels across that piece, as well as my 90. Hers measures exactly 27", so obviously not much bending going on there.
And after a couple hours of work, no core support and inner fenders that measure the same on both sides from the firewall to the end, from the firewall diagonally to each end, and from the center of the body mount to the end also! Not bad, even if I do say so myself, haha.
Passenger side inner fender (no damage)
Drivers side inner fender (had to straighten a few spots on this one)
Also I picked up some steel to make the new crossmember out of. I dont know what wall thickness most people used, but the steel yard had some 2.5"x2.5"x3/16" there, and it was a good price so I grabbed it. I figured 3/16" wall is thicker than the rest of the frame anyway, so it should be plenty good.
So, I think thats about it for now. Next step is to load it up on the trailer again to take it to a friends shop so I can cut out that front crossmember and weld the new one in. Then it comes back home so I can get the core supports and everything back in.
~T.J.
I got the last of the core support off today, straightened the inner fender on the drivers side some more, and got everything lined up pretty much right. I was impressed.
Here is a picture of the truck with the core support still on. It doesnt look that bad since I pried it back out straight to help with getting the radiator out, bumper off, etc.
And heres a couple pictures of the "bent frame". Mine measures exactly 27 1/4" from the inside of the frame channels across that piece, as well as my 90. Hers measures exactly 27", so obviously not much bending going on there.
And after a couple hours of work, no core support and inner fenders that measure the same on both sides from the firewall to the end, from the firewall diagonally to each end, and from the center of the body mount to the end also! Not bad, even if I do say so myself, haha.
Passenger side inner fender (no damage)
Drivers side inner fender (had to straighten a few spots on this one)
Also I picked up some steel to make the new crossmember out of. I dont know what wall thickness most people used, but the steel yard had some 2.5"x2.5"x3/16" there, and it was a good price so I grabbed it. I figured 3/16" wall is thicker than the rest of the frame anyway, so it should be plenty good.
So, I think thats about it for now. Next step is to load it up on the trailer again to take it to a friends shop so I can cut out that front crossmember and weld the new one in. Then it comes back home so I can get the core supports and everything back in.
~T.J.
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84Toyota4x4
Well-Known Member
I forgot to mention that we discovered a crack in the front cover the other day when we were first tearing it apart too. I think the impact from the radiator into the fan clutch/water pump actually cracked the front cover. Its just above the water pump, below the casting where the bolt goes down into the cover from the head under the dizzy drive gear.
Not a big deal since we needed to tear the front apart to replace the timing set anyway, so I'll just pop a new cover in when it goes back together, but I'm just glad I noticed it now, haha.
When she bought it, it had a rebuilt engine recently put in it. Well, I discovered that someone had used the wrong size timing cover bolts so one was basically falling out, others were ground on the ends to try and make them the right length, etc. One of them actually hit the tensioner arm which obviously caused some problems. They also over torqued the oil pan and the gasket is probably close to 50% mushed out, so thats getting replaced too. Its also getting some other stuff in the process, but thats all later in the project after the body is mostly back together.
~T.J.
Not a big deal since we needed to tear the front apart to replace the timing set anyway, so I'll just pop a new cover in when it goes back together, but I'm just glad I noticed it now, haha.
When she bought it, it had a rebuilt engine recently put in it. Well, I discovered that someone had used the wrong size timing cover bolts so one was basically falling out, others were ground on the ends to try and make them the right length, etc. One of them actually hit the tensioner arm which obviously caused some problems. They also over torqued the oil pan and the gasket is probably close to 50% mushed out, so thats getting replaced too. Its also getting some other stuff in the process, but thats all later in the project after the body is mostly back together.
~T.J.
84Toyota4x4
Well-Known Member
No, we don't already have the cover, but I think Im just gonna buy everything I need in a "package" from EngnBldr. Its like $150 for the cover, oil pump, water pump, and steel backed timing kit. Ive heard good things about his parts.
~T.J.
~T.J.
good plan.
T_MADD1
Well-Known Member
Looks great!
Alot less damage then I was thinking.
Alot less damage then I was thinking.
84Toyota4x4
Well-Known Member
Yeah, its barely anything really. Its a shame they totaled it :looser:
Hell, heres the "bad" fender
Like I said, mainly its just the core support, grill, bumper, radiator, hood and that tiny bit of fender, and some other misc stuff. Hell, none of the lights even broke. The shop came up with $2000 in parts, and stopped at $4000 in labor. Apparently I'm in the wrong industry. I should own a body shop.
~T.J.
Hell, heres the "bad" fender
Like I said, mainly its just the core support, grill, bumper, radiator, hood and that tiny bit of fender, and some other misc stuff. Hell, none of the lights even broke. The shop came up with $2000 in parts, and stopped at $4000 in labor. Apparently I'm in the wrong industry. I should own a body shop.
~T.J.
Hardly anything from our perspective, but for a body shop that's plenty of man hours and painting at least half the vehicle to "blend" it.
84Toyota4x4
Well-Known Member
True. I think the plan is to paint the hood, cowl, and fenders together, then if it works out, respray the whole thing down the road.
~T.J.
~T.J.
Moose
Well-Known Member
Lol, I like those wheels.
I have to agree with the measuring thing, measure a bajillion times! My old man DDs an '85 Yoter and over the years we've replaced the front sheetmetal (and some hard parts too) several times, due to cows, deer, rocks, etc. Each time we get a little faster and better, in fact I think we could get it all fixed up in a couple hours now! I agree with the off-brand parts being crappy too, that's what we've used since the truck is 2wd and worthless, and it's a major PITA to get everything somewhat lined up and looking decent. I don't have any input on the painting thing, I can't remember what we did last time, but it didn't work out all that well. Then or the time before, or the time before....
Post some progress pics though, and share what you do, it'll be cool to read!
I have to agree with the measuring thing, measure a bajillion times! My old man DDs an '85 Yoter and over the years we've replaced the front sheetmetal (and some hard parts too) several times, due to cows, deer, rocks, etc. Each time we get a little faster and better, in fact I think we could get it all fixed up in a couple hours now! I agree with the off-brand parts being crappy too, that's what we've used since the truck is 2wd and worthless, and it's a major PITA to get everything somewhat lined up and looking decent. I don't have any input on the painting thing, I can't remember what we did last time, but it didn't work out all that well. Then or the time before, or the time before....
Post some progress pics though, and share what you do, it'll be cool to read!
84Toyota4x4
Well-Known Member
Whats wrong with the wheels? I dont like them, and I have another set but we're waiting to buy tires to have them mounted on the new set. I just dont like the ones one there because you cant get a freaking impact socket (or lug wrench) on the lugs unless you use the thin walled ones, which I have none of. Ive always had to borrow one every time I pull the wheels. Not even my standard chrome ones slide in there.
Anyway, Im hoping that we can find a good fender and hood from a parts truck, but I think we're going to be using the after market core support pieces for "simplicity" during the install. The core support doesnt "align" much per say, so I figure a stock fender and hood would work well on it since none of those mounting points are being modified or replaced. Just the front mounting points for the other stuff are changing, but none of the stock bumper stuff is going back on anyway. As long as the grill, lights, and radiator fit and sit right, Ill be happy. I'm crossing my fingers, lol.
As for the painting, Im going to try and do that the best I can and do it right. The beauty of doing it myself is that if it gets all messed up or comes out shitty, Im not out nearly as much money. I can just pull the panels and try again. Once I get it right, Ill paint the rest of the truck too. Then, once Im REALLY good, Ill paint mine. Im just using hers for practice
~T.J.
Anyway, Im hoping that we can find a good fender and hood from a parts truck, but I think we're going to be using the after market core support pieces for "simplicity" during the install. The core support doesnt "align" much per say, so I figure a stock fender and hood would work well on it since none of those mounting points are being modified or replaced. Just the front mounting points for the other stuff are changing, but none of the stock bumper stuff is going back on anyway. As long as the grill, lights, and radiator fit and sit right, Ill be happy. I'm crossing my fingers, lol.
As for the painting, Im going to try and do that the best I can and do it right. The beauty of doing it myself is that if it gets all messed up or comes out shitty, Im not out nearly as much money. I can just pull the panels and try again. Once I get it right, Ill paint the rest of the truck too. Then, once Im REALLY good, Ill paint mine. Im just using hers for practice
~T.J.
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84Toyota4x4
Well-Known Member
Well, finally some more progress!
We got all the parts we needed to replace the cracked front cover, so I got those installed a while back. New front cover, oil pump, water pump, timing kit (steel rail), head gasket, intake/exhaust gaskets, etc.
We also just went and picked up a core support from Jeepster72 last night, and I got it all stripped down to what I needed (it was sawzalled off with inner fenders and all still attached). Heres a couple pictures of what it looked like after I got it stripped down and washed off.
Then, I got all the spot welds on everything all ground flush again, and got the core support mocked up on the truck.
Before:
After:
Then I cut the front crossmember to get the frame spread back out where it needed to be (1/4" out). Wasnt too bad until my grinder died with about 1" of frame left to cut. I had to bust out the hacksaw. Anyway, I got it cut, and spread it back out with my hi-lift. Not too bad at all. Its about 1/32 too narrow, but I figure when I cut the new piece, Ill cut it exactly right, then just pop it in. Should be perfect.
After the frame was the right width again, I started to see how well the new core support lined up with the existing inner fenders and body mounts. After a little tweaking, I got the inner fenders to line up pretty dang good. Heres what I ended up with after some tweaking. Its not final since Im going to pull it off again to replace the crossmember for easier access. After thats done I'll do the final install.
Passenger side (non damaged):
Drivers side (damaged and straightened):
I discovered that the core support itself was a little bent (on the drivers side of course, haha), but it straightened out just fine. That gap you see on the drivers side just below the headlight bucket will go away once the core support is pressed into the inner fender.
I also took some measurements after it was mocked up again, and the length from firewall to end of core support is 33.5" on both sides exactly, and the diagonals are within 1/8" each. Not too bad!
Anyway, its coming along slowly! Between this, my new 4Runner thats getting the V6 to 4cyl conversion, and my truck, its amazing I get ANYTHING done, haha.
~T.J.
We got all the parts we needed to replace the cracked front cover, so I got those installed a while back. New front cover, oil pump, water pump, timing kit (steel rail), head gasket, intake/exhaust gaskets, etc.
We also just went and picked up a core support from Jeepster72 last night, and I got it all stripped down to what I needed (it was sawzalled off with inner fenders and all still attached). Heres a couple pictures of what it looked like after I got it stripped down and washed off.
Then, I got all the spot welds on everything all ground flush again, and got the core support mocked up on the truck.
Before:
After:
Then I cut the front crossmember to get the frame spread back out where it needed to be (1/4" out). Wasnt too bad until my grinder died with about 1" of frame left to cut. I had to bust out the hacksaw. Anyway, I got it cut, and spread it back out with my hi-lift. Not too bad at all. Its about 1/32 too narrow, but I figure when I cut the new piece, Ill cut it exactly right, then just pop it in. Should be perfect.
After the frame was the right width again, I started to see how well the new core support lined up with the existing inner fenders and body mounts. After a little tweaking, I got the inner fenders to line up pretty dang good. Heres what I ended up with after some tweaking. Its not final since Im going to pull it off again to replace the crossmember for easier access. After thats done I'll do the final install.
Passenger side (non damaged):
Drivers side (damaged and straightened):
I discovered that the core support itself was a little bent (on the drivers side of course, haha), but it straightened out just fine. That gap you see on the drivers side just below the headlight bucket will go away once the core support is pressed into the inner fender.
I also took some measurements after it was mocked up again, and the length from firewall to end of core support is 33.5" on both sides exactly, and the diagonals are within 1/8" each. Not too bad!
Anyway, its coming along slowly! Between this, my new 4Runner thats getting the V6 to 4cyl conversion, and my truck, its amazing I get ANYTHING done, haha.
~T.J.
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84Toyota4x4
Well-Known Member
Oh also, should I put anything between the panels before they get spot welded back together? I know I can use the body seam filler after theyre together to seal them (that caulking stuff), but does anything go between them before hand? I don't think there was anything stock, so I would think not? Also, I want to get that strip caulk stuff thats on top of the inner fenders and replace that. I know Wesco has that stuff, along with the filler caulk.
Im gonna need to re-undercoat the fenders in the wheel wells since a lot flaked off in the process of straightening the inner fender, anyone have a brand preference of stuff that works well?
Once its all mounted up, I'm gonna strip the inner fenders of parts, and re-paint them I think since a lot of paint flaked when I was straightening stuff out too. That and the core support needs to be painted white as well.
~T.J.
Im gonna need to re-undercoat the fenders in the wheel wells since a lot flaked off in the process of straightening the inner fender, anyone have a brand preference of stuff that works well?
Once its all mounted up, I'm gonna strip the inner fenders of parts, and re-paint them I think since a lot of paint flaked when I was straightening stuff out too. That and the core support needs to be painted white as well.
~T.J.
T_MADD1
Well-Known Member
Yes, spray some weld through primer between the two panels before you weld them up.Probably any autoparts store has it, I know NAPA does.
It comes in a airasol(sp?) can.
84Toyota4x4
Well-Known Member
Got some pictures of the 4Runner from the last post. I got the front cross member cut out finally, and got the new piece sized up and fit in. Its just tacked in until my new welder gets here tomorrow, but it looks good.
After the welder gets here tomorrow, of course I have to work, so next days off will be spent welding the cross member in, then getting the core support welded in, then just reassembly finally.
I still have to lift the motor to do the oil pan gasket, then get some radiator hoses for it, but mostly its almost ready to run again!
~T.J.
New crossmember:
Passenger side:
Drivers side:
After the welder gets here tomorrow, of course I have to work, so next days off will be spent welding the cross member in, then getting the core support welded in, then just reassembly finally.
I still have to lift the motor to do the oil pan gasket, then get some radiator hoses for it, but mostly its almost ready to run again!
~T.J.
New crossmember:
Passenger side:
Drivers side:
Looking good. One thing you might do to help with that gap on the inside of either side of the new crossmember is use a chunk of angle iron on either side to help tie it into the frame rail, put the point of the angle on the gap and the flats against the frame rail and crossmember. Something around 3/16" thick by ~3" and taper the ends should work well. Just an idea. On the driver's side you could incorporate it into a steering box plate for the inevitable future axle swap :;
84Toyota4x4
Well-Known Member
Interesting idea. I'll keep it mind.
As for the axle swap, its coming. Slowly but surely, its coming... She just has to save up for it first, haha.
One thing at a time though, first we get it on the road. Then we go back and "beautify" it (body and paint, and finishing touches). Then we tear into it again for modifications.
We got some free parts (hood, fender, and grill) a while back, and both panels are white, but both have dents and the grill is cracked, so we're still looking for good ones. We're just gonna run what we have for now, but keep a keen eye out for good parts so we can swap them around and get the best combo, then paint it all to match.
Oh well, slow but somewhat steady progress...
~T.J.
As for the axle swap, its coming. Slowly but surely, its coming... She just has to save up for it first, haha.
One thing at a time though, first we get it on the road. Then we go back and "beautify" it (body and paint, and finishing touches). Then we tear into it again for modifications.
We got some free parts (hood, fender, and grill) a while back, and both panels are white, but both have dents and the grill is cracked, so we're still looking for good ones. We're just gonna run what we have for now, but keep a keen eye out for good parts so we can swap them around and get the best combo, then paint it all to match.
Oh well, slow but somewhat steady progress...
~T.J.
