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LJ70 Build Thread!
- Thread starter Ben
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made a bit more progress today. 
firstly i syphoned all the fuel out of the tank, about 20litres of diesel veg mix.
later i realised there is a handy drain plug on the bottom of the tank, just like the drain plugs on the diffs.
i then took the tank and guard outside and gave them a good clean with the steam pressure washer.
my mates turned up and expressed there unhappiness about me coating everthing in waxoil and underseal, when i should have waited till all the bodywork had been done.
they then carried on with the bodywork.
firstly he cut the small remaining bit of rot out of the back of the sill.
he then cut and bent a piece of metal to fit perfectly in place.
he then welded it in place.
while they were doing the bodywork, i cooked breakfast. sausage and egg sandwiches.
meanwhile my mate finished off the other side of the arch, the bit where the new arch panel meets the back of the truck.
after breakfast it was time to begin on the other side, the off side rear arch, which has suffered from rot a lot worse than the other side.
first they began cutting out the rot.
the new panel needed a bit of trimming to make it fit nicely.
while they were fettling the new panel i cooked lunch. bacon and egg sandwiches.
bit more trimming of the new panel.
new panel clamped in place.
looking good but needed a bit more fettling on the back bit.
i then used a hammer and old chisel to remove the plates the previous owner had had welded onto the sill for the mot. as i thought the plate had been welded straight over the rusty hole, with no effort to remove or treat the rot.
at this point my mates had to go home, so they told me what i needed to do to repair the sill.
so i used the wire brush attachment in the grinder to take the paint off and find where was solid metal surrounding the rot.
i then marked and cut out all the rot.
the axle, trailing arms, and panhard rod are almost ready to go back on.
i then used a scraper and wire brush to remove any flakes of rust i could see on the fuel tank.
before treating it all with rust killer.
before doing the same with the tank guard.
had a bit of a tidy up and re organised the workshop a bit, added a few shelves, and fitted some metal boards to the wall for the plastic bins to clip on.
i would like to do more on my truck tomorrow but i cant as im going laning in the lakes with Mitch in his 90.
firstly i syphoned all the fuel out of the tank, about 20litres of diesel veg mix.
later i realised there is a handy drain plug on the bottom of the tank, just like the drain plugs on the diffs.
i then took the tank and guard outside and gave them a good clean with the steam pressure washer.
my mates turned up and expressed there unhappiness about me coating everthing in waxoil and underseal, when i should have waited till all the bodywork had been done.
they then carried on with the bodywork.
firstly he cut the small remaining bit of rot out of the back of the sill.
he then cut and bent a piece of metal to fit perfectly in place.
he then welded it in place.
while they were doing the bodywork, i cooked breakfast. sausage and egg sandwiches.
meanwhile my mate finished off the other side of the arch, the bit where the new arch panel meets the back of the truck.
after breakfast it was time to begin on the other side, the off side rear arch, which has suffered from rot a lot worse than the other side.
first they began cutting out the rot.
the new panel needed a bit of trimming to make it fit nicely.
while they were fettling the new panel i cooked lunch. bacon and egg sandwiches.
bit more trimming of the new panel.
new panel clamped in place.
looking good but needed a bit more fettling on the back bit.
i then used a hammer and old chisel to remove the plates the previous owner had had welded onto the sill for the mot. as i thought the plate had been welded straight over the rusty hole, with no effort to remove or treat the rot.
at this point my mates had to go home, so they told me what i needed to do to repair the sill.
so i used the wire brush attachment in the grinder to take the paint off and find where was solid metal surrounding the rot.
i then marked and cut out all the rot.
the axle, trailing arms, and panhard rod are almost ready to go back on.
i then used a scraper and wire brush to remove any flakes of rust i could see on the fuel tank.
before treating it all with rust killer.
before doing the same with the tank guard.
had a bit of a tidy up and re organised the workshop a bit, added a few shelves, and fitted some metal boards to the wall for the plastic bins to clip on.
i would like to do more on my truck tomorrow but i cant as im going laning in the lakes with Mitch in his 90.
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was in the workshop at 7.30am today and got cracking with the bodywork. 
first i cut some steel using the guillotine.
then i used the bender to bend it.
needed a bit more trimming.
i then folded up the bottom section. im having to make it in 2 sections as theres a step in the sill profile and i wouldnt be able to replicate this if i made it out of one piece.
then i realised id made a slight error. the panels fitted and were the perfect profile, but the top piece needed to extend down further to give me something to spot weld to.
so i measured and marked and made another one.
new panel in place, i marked where it wanted the holes punching for spot welding.
gave the existing metal a quick go over with the grinder.
then i was ready for the new metal to go in, so i clamped and then welded in the new metal.
next i cut and bent the next piece of metal which is curved. i also had to bend some tabs on it at 90degrees to give me something to spot weld.
welded in place.
next i clamped the new arch in place, so that i could see how much more metal needed to go in to close off the final area on the sill section.
so i cut and bent the last piece. i used a piece of scaffold tube to help get a nice curve on the metal when i bent it.
clamped in place and ready to weld.
i then spot welded it in place. once that was done i removed the clamps and began welding all the edges of all the metal together, until the bloody gas ran out. going to pick up another couple of bottles of gas tomorrow.
tried the panel back in place.
absolutely spot on. all the lines and angles are perfect.
as i couldnt do anymore welding i got some more of the paint work done.
i gave the fuel tank and guard a good coat of paint.
and gave the rear trailing arms and panhard rod another coat.
i then did a bit more undersealing underneath the truck, before i ran out.
so tomorrow i need to get more welding gas, and more waxoil and underseal.
first i cut some steel using the guillotine.
then i used the bender to bend it.
needed a bit more trimming.
i then folded up the bottom section. im having to make it in 2 sections as theres a step in the sill profile and i wouldnt be able to replicate this if i made it out of one piece.
then i realised id made a slight error. the panels fitted and were the perfect profile, but the top piece needed to extend down further to give me something to spot weld to.
so i measured and marked and made another one.
new panel in place, i marked where it wanted the holes punching for spot welding.
gave the existing metal a quick go over with the grinder.
then i was ready for the new metal to go in, so i clamped and then welded in the new metal.
next i cut and bent the next piece of metal which is curved. i also had to bend some tabs on it at 90degrees to give me something to spot weld.
welded in place.
next i clamped the new arch in place, so that i could see how much more metal needed to go in to close off the final area on the sill section.
so i cut and bent the last piece. i used a piece of scaffold tube to help get a nice curve on the metal when i bent it.
clamped in place and ready to weld.
i then spot welded it in place. once that was done i removed the clamps and began welding all the edges of all the metal together, until the bloody gas ran out. going to pick up another couple of bottles of gas tomorrow.
tried the panel back in place.
absolutely spot on. all the lines and angles are perfect.
as i couldnt do anymore welding i got some more of the paint work done.
i gave the fuel tank and guard a good coat of paint.
and gave the rear trailing arms and panhard rod another coat.
i then did a bit more undersealing underneath the truck, before i ran out.
so tomorrow i need to get more welding gas, and more waxoil and underseal.
Red Oktober
Well-Known Member
Looks great Ben
what paint are you using for the radius arms/panhard rod ??
what paint are you using for the radius arms/panhard rod ??
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thanx Carl, been using rustoleum.
http://www.rustoleum.co.uk/products
this one.
http://www.rustoleum-mathys.co.uk/produ ... OTH_id1190
http://www.rustoleum.co.uk/products
this one.
http://www.rustoleum-mathys.co.uk/produ ... OTH_id1190
Red Oktober
Well-Known Member
ben said:thanx Carl, been using rustoleum.
http://www.rustoleum.co.uk/products
this one.
http://www.rustoleum-mathys.co.uk/produ ... OTH_id1190
Excellent ... cheers mate
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thanks guys.
so the reason why i was able to spend all day working on my truck sunday, instead of laning in the lakes as planned..........................................
Mitch picked me up at 6.15am and we set off to meet the others 100miles away north.
2 miles up the road and 15mins later the landys front diff decided to explode and burst out of the axle casing.
luckily there was a toyota to the rescue, in the form of my mate in his hilux who very kindly got up at 6.30am on a sunday and came and towed us back.
the other lads didnt have much more luck either. it was a very late day and included 2 AA vehicles to get the one truck home.
the full story on the rest of the days laning is here:-
http://www.bits4vits.co.uk/store/the-la ... g_133.html
so the reason why i was able to spend all day working on my truck sunday, instead of laning in the lakes as planned..........................................
Mitch picked me up at 6.15am and we set off to meet the others 100miles away north.
2 miles up the road and 15mins later the landys front diff decided to explode and burst out of the axle casing.
luckily there was a toyota to the rescue, in the form of my mate in his hilux who very kindly got up at 6.30am on a sunday and came and towed us back.
the other lads didnt have much more luck either. it was a very late day and included 2 AA vehicles to get the one truck home.
the full story on the rest of the days laning is here:-
http://www.bits4vits.co.uk/store/the-la ... g_133.html
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sae70 said:Blimey! What a busy day
hopefully we will all have more luck next month, on are next trip back to the lakes. just hope my trucks finished in time.
i did a bit more on it tonight. to speed things up a bit i decided to fit the other panel myself.
first i trimmed a bit more off the panel, as my mate had told me needed doing.
i then punched all the holes in the new panel ready for spot welding, and clamped it in place.
spot welded to the truck.
i then had a look at the replacment door i picked up yesterday off Carl. (thanks again mate
)i started scraping the rust off, and a few holes appeared.
once i get all the rust sorted, and the holes repaired, should make a good replacement door.
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day 22 of the re-build and i feel i really need to push on, or else im not going to meet my 1 month dead line, which is how long ive got the workshop for. 
so today i worked for 14hours on it.
my body work mates wernt able to work today due to other commitments, but they did kindly drop in and go through a few bits with me, and finish welding the drivers side panel on. they also got some filler on the passenger side panel
after my mates had gone, i had a firm understanding of what i needed to do, in order to finish all the welding.
id almost finished welding the passenger side panel, when i found a small area of rot, inside the arch at the back near the body mount.
my mates have told me that the only way to get rid of rot is to cut it out, so out with the angle grinder and a thin slitting disc.
and then i welded in new steel.
so with the passenger side all done, i turned my attention to the drivers side.
first i needed to fill in the gap between the new panel and the body, as the original metal that was there had all been cut out to remove the rot.
so i marked the sheet steel.
cut it with the grinder, and then bent it using the bender.
after punching the holes in it, it was ready to weld in place.
that piece in, it was on to the next piece.
this piece required a few carefully placed slits, to allow the panel to bend to the contour of the new panel.
next few pieces in.
next it was time to turn my attention to what is by far the worst area on the whole truck for rot. right up inside the rear arch where the fuel filler neck sits.
so after removing the guard from my 4" angle grinder to allow better access in the tight space, i began cutting every spec of rot out!
already quite a pile of rusty toyota forming on the floor.
rot all out, it was time to start welding in new metal.
new panel ready to be fitted.
new panel in place.
next panel.
had to drill a hole for cables.
panel welded in place.
next panel.
so drivers side is almost finished.
and passenger side now has filler on.
after much discussion in my engine thread.
viewtopic.php?f=22&t=11339
i decided to buy a 3litre UK model toyota 4-runner, which i will take the engine out of and put in mine.
so here is the donor vehicle.
its not in bad condition apart from a little rust on the arches. it drives very nicely and all the electrics and everything work perfectly.
i have been tempted to insure it and drive it for a bit until i get around to removing the engine, as its got a long mot and a few months tax, but i dont think its a good idea as i think theres a good chance id get too attached to it, and decide i love it too much to rip its heart out!
so to conclude im hoping to finish the body work tomorrow, then i can finish re-fitting the rear axle and fuel tank, and then turn the truck around and start stripping the front down.
engine transplant will have to wait till after the Lincomb weekend in October.
once the engines in i want some new wheels with bigger off set, and KAM diff locks and lower ratio diff gears.
also need to finsh my rock sliders and build my rear bumper.
im also going to have a 3" stainless steel exhaust system made once the new engine is fitted.
so today i worked for 14hours on it.
my body work mates wernt able to work today due to other commitments, but they did kindly drop in and go through a few bits with me, and finish welding the drivers side panel on. they also got some filler on the passenger side panel
after my mates had gone, i had a firm understanding of what i needed to do, in order to finish all the welding.
id almost finished welding the passenger side panel, when i found a small area of rot, inside the arch at the back near the body mount.
my mates have told me that the only way to get rid of rot is to cut it out, so out with the angle grinder and a thin slitting disc.
and then i welded in new steel.
so with the passenger side all done, i turned my attention to the drivers side.
first i needed to fill in the gap between the new panel and the body, as the original metal that was there had all been cut out to remove the rot.
so i marked the sheet steel.
cut it with the grinder, and then bent it using the bender.
after punching the holes in it, it was ready to weld in place.
that piece in, it was on to the next piece.
this piece required a few carefully placed slits, to allow the panel to bend to the contour of the new panel.
next few pieces in.
next it was time to turn my attention to what is by far the worst area on the whole truck for rot. right up inside the rear arch where the fuel filler neck sits.
so after removing the guard from my 4" angle grinder to allow better access in the tight space, i began cutting every spec of rot out!
already quite a pile of rusty toyota forming on the floor.
rot all out, it was time to start welding in new metal.
new panel ready to be fitted.
new panel in place.
next panel.
had to drill a hole for cables.
panel welded in place.
next panel.
so drivers side is almost finished.
and passenger side now has filler on.
after much discussion in my engine thread.
viewtopic.php?f=22&t=11339
i decided to buy a 3litre UK model toyota 4-runner, which i will take the engine out of and put in mine.
so here is the donor vehicle.
its not in bad condition apart from a little rust on the arches. it drives very nicely and all the electrics and everything work perfectly.
i have been tempted to insure it and drive it for a bit until i get around to removing the engine, as its got a long mot and a few months tax, but i dont think its a good idea as i think theres a good chance id get too attached to it, and decide i love it too much to rip its heart out!
so to conclude im hoping to finish the body work tomorrow, then i can finish re-fitting the rear axle and fuel tank, and then turn the truck around and start stripping the front down.
engine transplant will have to wait till after the Lincomb weekend in October.
once the engines in i want some new wheels with bigger off set, and KAM diff locks and lower ratio diff gears.
also need to finsh my rock sliders and build my rear bumper.
im also going to have a 3" stainless steel exhaust system made once the new engine is fitted.
Red Oktober
Well-Known Member
Wow ... thats some work gone into your 70 Ben .... one month seems very short considering the work you've got going on there
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thanks Carl,
trouble is in the week i sometimes dont get back from site, depending on where in the country im working and what im doing till 7,8,9,10pm etc.
so its difficult to get as much done in the week as id like.
im hoping to have the front stripped down and rebuilt over this next week, leaving next weekend free to get the truck sprayed, if my bodywork mates are able to come and do the spraying.
then weekend after that im helping my boss fit his new ashcroft lockers and shafts, ready for laning in the lake district the week after.
trouble is in the week i sometimes dont get back from site, depending on where in the country im working and what im doing till 7,8,9,10pm etc.
so its difficult to get as much done in the week as id like.
im hoping to have the front stripped down and rebuilt over this next week, leaving next weekend free to get the truck sprayed, if my bodywork mates are able to come and do the spraying.
then weekend after that im helping my boss fit his new ashcroft lockers and shafts, ready for laning in the lake district the week after.
Looks like alot of fun to had there Ben 
Those battery clamps on that 4-Runner look very familiar
If the top clamp, hook bolt, plastic tray & inner wing battery shelf are the same as fitted on the Collie then I know a few Prado owners would / may be interested in them
Those battery clamps on that 4-Runner look very familiar
If the top clamp, hook bolt, plastic tray & inner wing battery shelf are the same as fitted on the Collie then I know a few Prado owners would / may be interested in them 
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