Long overdue project.

Members' DIY projects
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Froll
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Joined: Sat Oct 13, 2012 10:13 pm
Town: Vioolsdrift
Vehicle: 1995 2,4 SFA Hilux,Home made snorkel,Home made front bumper .
Real Name: Roger
ORRA Call Sign: N/A

Sat Mar 26, 2016 9:01 pm

Today I got it right to start my long awaited overhaul of my truck.It is going to take quite a while due to the amount of work and only being able to work basically 1 day a week and a few nights. I will post pics as I go along. This will also be a first time for me with removing a roof skin and rust removal that needs pieces removed and replaced. I have done lots of minor rust removal before, so I am holding thumbs to a good job.
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IMG_0660.jpg

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ChrisF
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Sat Mar 26, 2016 9:17 pm

Voorspoed !

seker jy gaan dit goed doen.

Vrek baie werk vir iemand wat al klaar so besig is ...

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louis fourie
LR4WD, Lockers, Crawler Gears
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Town: Pretoria
Vehicle: 2003 Hilux Raider Facelift D/C 3.0 KZTE
Real Name: Louis
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Sun Mar 27, 2016 8:56 am

ChrisF wrote:
Vrek baie werk vir iemand wat al klaar so besig is ...
Ja, die meeste van ons is mos maar suckers vir punishment

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pietpetoors
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Sun Mar 27, 2016 9:42 am

Sterkte
Only Dead Fish Go With The Flow!
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1999 Hilux 2.7i 4x4 Raider DC. Rear diff-lock, Red Peppor Bull Bar and rock sliders, 31" Cooper ST, Snorkel, Alu-Canopy, VHF Kirisun radio, West Coast Rust, Mikem Rear Suspension, Ball Joint Spacers in front, 25watt LED Spots

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CasKru
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Sun Mar 27, 2016 12:24 pm

Sterkte
To God be the glory

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Knuppel
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Sun Mar 27, 2016 12:55 pm

Sal hierdie ronte maar in my stoel sit en kyk, sterkte
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Froll
Monster Truck
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Town: Vioolsdrift
Vehicle: 1995 2,4 SFA Hilux,Home made snorkel,Home made front bumper .
Real Name: Roger
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Sun Mar 27, 2016 5:33 pm

Dankie ouens, ja Marius, jy het die ondervinding, jy kan nou geniet soos ek jou post geniet het.

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Baasvark
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Sun Mar 27, 2016 7:17 pm

Strongs! Keep us posted.

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Mud Dog
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Vehicle: '90 SFA Hilux DC 4X4, Full OME, 110mm lift. Brospeed branch, 50mm ss freeflow exhaust. 30 x 9.5 Discoverer S/T's on Viper mags. L/R tank. (AWOL) '98 LTD 2.4 SFA, dual battery system. Dobinson suspension, LR tanks, 31" BF mud's.
Real Name: Andy

Sun Mar 27, 2016 8:31 pm

I have no doubt that you'll do a sterling job, Roger! Good luck and enjoy! :thumbup: :winkx:
When your road comes to an end ...... you need a HILUX!.

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Life is like a jar of Jalapeño peppers ... what you do today, might burn your ass tomorrow.
Don't take life too seriously ..... no-one gets out alive.
It's not about waiting for storms to pass. It's about learning to dance in the rain.
And be yourself ..... everyone else is taken!

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Oupa Stig
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Tue Mar 29, 2016 3:20 pm

Geniet dit!
I feel a lot less wise at 45 than I did at 15.

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Witvos
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Wed Mar 30, 2016 7:47 am

Geniet dit. Ek hou dop hier uit Kaapfontein wat gebeur!

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Froll
Monster Truck
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Vehicle: 1995 2,4 SFA Hilux,Home made snorkel,Home made front bumper .
Real Name: Roger
ORRA Call Sign: N/A

Sat Apr 02, 2016 8:46 pm

Stripped out the inside today. Seats, carpets and 80% of the dash. Am very relieved to see that there is no rust in the floor. Will post some pics tomorrow night as our power is off for the day tomorrow for maintenance.

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Knuppel
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Sun Apr 03, 2016 9:03 am

:thumbup: Waiting for those pics!
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Thunder02
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Sun Apr 03, 2016 9:24 am

Have fun, you can't withhold info, are you changing color, keeping her standard?
Plenty pics need to follow.
Not all those who wander are lost!

Scout motto:be prepared....
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ChrisF
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Sun Apr 03, 2016 11:07 am

Knuppel wrote::thumbup: Waiting for those pics!
what he said .... :twisted:

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Froll
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Joined: Sat Oct 13, 2012 10:13 pm
Town: Vioolsdrift
Vehicle: 1995 2,4 SFA Hilux,Home made snorkel,Home made front bumper .
Real Name: Roger
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Sun Apr 03, 2016 11:06 pm

Our power only came on now at 10 30. So a few pics as promised. Yes Niel I am going to change colour, to L/C beige. The good bit.......
Attachments
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Froll
Monster Truck
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Posts: 3281
Joined: Sat Oct 13, 2012 10:13 pm
Town: Vioolsdrift
Vehicle: 1995 2,4 SFA Hilux,Home made snorkel,Home made front bumper .
Real Name: Roger
ORRA Call Sign: N/A

Sun Apr 03, 2016 11:09 pm

And the bad side of things......
Attachments
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IMG_0629.jpg
IMG_0677.jpg
IMG_0678.jpg

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Knuppel
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Real Name: Marius

Mon Apr 04, 2016 12:09 pm

Your floor looks good, very good. I am surprised that the pillars are so rusted. Has it had the roof replaced previously perhaps?

Also see you still have the gearlock, do you still use it or is it a white elephant?
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Froll
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Joined: Sat Oct 13, 2012 10:13 pm
Town: Vioolsdrift
Vehicle: 1995 2,4 SFA Hilux,Home made snorkel,Home made front bumper .
Real Name: Roger
ORRA Call Sign: N/A

Mon Apr 04, 2016 8:56 pm

Yes Marius, I am very happy about the floor. The roof may have been replaced before I am not sure.The rust problem seems to be on the top of the two front pillars and in the gutters where the roof joins. All I know is it is going to be a s..t job to remove. The gear lock, I have never used as we dont have that kind of threat here by us. I am probably going to take it out. If you are looking for one, I will let you know.

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Mud Dog
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Vehicle: '90 SFA Hilux DC 4X4, Full OME, 110mm lift. Brospeed branch, 50mm ss freeflow exhaust. 30 x 9.5 Discoverer S/T's on Viper mags. L/R tank. (AWOL) '98 LTD 2.4 SFA, dual battery system. Dobinson suspension, LR tanks, 31" BF mud's.
Real Name: Andy

Tue Apr 05, 2016 12:37 am

It's not uncommon for an SFA to have A-pillar cracks in exactly that spot. This is almost certainly not a roof replacement - that is a factory seam weld that has popped due to some "abuse' over the years where the cab has been forced to flex too far or too often. I've had it and seen countless others that have cracked in exactly that same spot. Not an easy repair, but possible. Best of luck! :thumbup:
When your road comes to an end ...... you need a HILUX!.

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Life is like a jar of Jalapeño peppers ... what you do today, might burn your ass tomorrow.
Don't take life too seriously ..... no-one gets out alive.
It's not about waiting for storms to pass. It's about learning to dance in the rain.
And be yourself ..... everyone else is taken!

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Froll
Monster Truck
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Tue Apr 05, 2016 7:34 am

Yes Andy, it seems tome like someone has hammered in the pillars where it was rusted and then put about 10 mm of body putty over it.It all comes down to me not checking it properly when I bought the truck.I will see what I am dealing with once I have removed the roof skin. :o:

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ChrisF
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Wed Apr 06, 2016 9:59 pm

Question - is it possible/safe/practical to try and repair those pillars with the windscreen in place ?

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Mud Dog
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Vehicle: '90 SFA Hilux DC 4X4, Full OME, 110mm lift. Brospeed branch, 50mm ss freeflow exhaust. 30 x 9.5 Discoverer S/T's on Viper mags. L/R tank. (AWOL) '98 LTD 2.4 SFA, dual battery system. Dobinson suspension, LR tanks, 31" BF mud's.
Real Name: Andy

Thu Apr 07, 2016 12:59 am

Nah Chris, the rust will extend well behind the screen seals - it will have to come out. There will also be some welding work (even without replacing the roof skin), - it has to be stripped clean.
When your road comes to an end ...... you need a HILUX!.

Image
Image

Life is like a jar of Jalapeño peppers ... what you do today, might burn your ass tomorrow.
Don't take life too seriously ..... no-one gets out alive.
It's not about waiting for storms to pass. It's about learning to dance in the rain.
And be yourself ..... everyone else is taken!

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Froll
Monster Truck
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Joined: Sat Oct 13, 2012 10:13 pm
Town: Vioolsdrift
Vehicle: 1995 2,4 SFA Hilux,Home made snorkel,Home made front bumper .
Real Name: Roger
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Thu Apr 07, 2016 9:18 pm

Yes Chris, I will be removing the screen and the roof skin to replace the metal that is rusted.
Andy it does not look like the rust has gone right in as I moved the screen rubber and ti looks not to bad, will be sure once the screen is out.
I am off tomorrow for working on Monday , so I will see how far I can get this weekend.

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4x4BEES
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Real Name: Kevin

Fri Apr 08, 2016 7:55 am

Sterkte met die besige tyd wat voorle Roger, sal seker n groot sukses wees soos al jou vorige projekte.

P.S. L/C beige sal be... lyk

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Froll
Monster Truck
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Joined: Sat Oct 13, 2012 10:13 pm
Town: Vioolsdrift
Vehicle: 1995 2,4 SFA Hilux,Home made snorkel,Home made front bumper .
Real Name: Roger
ORRA Call Sign: N/A

Fri Apr 08, 2016 3:33 pm

So today I got some stripping done.
I will strip the engine side of things tomorrow and try to lift the cab off next weekend. Not all of that dark brown you see in the pics is rust, some of it is dried glue from gluing the roof liner. Just 2 spot of surface rust on the water drain channels on the passenger side. The biggest problem is the rust on the driver side roof gutter and the a- pillar which has been butchered quite bad, their is a join in the pillar in the middle that I cannot think why as there is no join at the top or bottom.Not looking so good at the moment. But will see what can be done to ease this trucks pain.
Attachments
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A lot of rust damage on driver side gutter
IMG_0688.jpg
The driver side a-frame has been joined in the middle. Has been butchered quite bad
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The passenger side a-pillar is not too bad
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The bottom of windscreen has minimal surface rust
IMG_0680.jpg
The drain vents are 99% rust free
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IMG_0691.jpg
The roof skin has been replaced before

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mcw
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Fri Apr 08, 2016 3:56 pm

Hi Rodgers
there is a place in Krugersdorp near me that sell body panels ,paint etc for older vehicles ,they are not OEM but seems decent enough ,if you want me to find out about any replacement parts you need let me know ,i am going to buy a bonnet from them,was clobbered by hail.

Martin

Thabogrobler
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Sun Apr 10, 2016 3:23 pm

Before you refit the roofining, toss out that material thingies and cover the whole roof with this thin rubber matrasses that the hikers use. It makes a huge difference to the heat build up in your car!

And also cover the floor an firewall with it. Isolates sound and heat and is dirt cheap - maybe stick some to the door skins aswell?
'02 KZ 'Lux. Cooled. Chipped. Onca'd. Cherished!

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Knuppel
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Real Name: Marius

Sun Apr 10, 2016 5:40 pm

Progress!
That rust looks nasty on the A pillar. Hope you get rid of it all.
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Froll
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Town: Vioolsdrift
Vehicle: 1995 2,4 SFA Hilux,Home made snorkel,Home made front bumper .
Real Name: Roger
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Sun Apr 10, 2016 7:28 pm

Thanks Martin, there are places in Cape town where I can get a roof skin, bonnet and so on. What I really need is the front a pillars and the gutters.
Yes Thabo that material does not mean anything, I think it is put on like that to get rid of the metal noise.
Yes Marius, the rust is nasty, I will have to look for old A- pillars maybe. I have moved the truck into the garage and loosend everything to remove the cab which I will do next weekend. I have made castor wheels to move the cab around. So I will fit them and then the chassis is also free to clean up.

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sir shrek
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Real Name: Claude

Mon Apr 11, 2016 4:07 pm

Stay strong. Don't fade out like I did. If you decide to look for another cab, give me a call.
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UGLY LIKE SHREK,STRONG LIKE RUSSIA

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Froll
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Sat Apr 16, 2016 12:17 pm

Ok, so today I removed the cab and fitted the castor wheels. I cut the roof skin off and started removing the last bits where it is spot welded. The gutters have the most rust in and will have to be replaced. Apart from the front pillars the rest does not look bad, much better than I expected. Now I must finish removing the gutters and clean up the rest of the steel work. I will try and find new gutters, but if I cant I will make new ones, they dont seem to much hassel to make ( I hope).
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Knuppel
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Sat Apr 16, 2016 1:48 pm

:subscribed:
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ChrisF
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Sat Apr 16, 2016 4:47 pm

netjies.

Jy vorder mooi Roger.

VASBYT !


As jy klaar is het daai wa nog n hele paar jaar bygekry :)

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Froll
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Vehicle: 1995 2,4 SFA Hilux,Home made snorkel,Home made front bumper .
Real Name: Roger
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Sat Apr 23, 2016 6:37 pm

Got a bit of work done today. Removed the l/side gutter and cleaned up the steel. Most of the rust was concentrated in the gutter itself and very little in the frame. will get my steel plate in the week hopefully then I can start making the replacement pieces.
Attachments
IMG_0718.jpg
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IMG_0716.jpg
IMG_0715.jpg
IMG_0714.jpg

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Haboob
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Thu Apr 28, 2016 12:04 pm

Doing well Roger, you will really appreciate the end result.
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HABOOB means "Dust Storm"

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Froll
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Real Name: Roger
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Sun May 08, 2016 4:57 pm

I got a bit of work done yesterday. Cut out some of the rusted section on the passenger side and tried my hand at bending a replacement piece. I got it pretty close. Will try welding it in next weekend. Still a small piece to cut out, but it has to be made in 2 pieces.
I also came up with an idea of making a solid roof lining like the new vehicles instead of making a lining with the steel rods in it. I made a mold to cast a piece of curved fiberglass. I have to polish it for a few days with release agent before I can cast it. I have some idea in the back of my mind of fitting the radio speakers in the roof. I dont know if it a good idea or if it is viable to do this. Maybe it is not a bright idea and would love to hear some thoughts from other members.
Attachments
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The Legend
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Real Name: Dawie
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Sun May 08, 2016 5:32 pm

It looks very good so far Rodger. You are on the right track :thumbup:
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Mud Dog
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Vehicle: '90 SFA Hilux DC 4X4, Full OME, 110mm lift. Brospeed branch, 50mm ss freeflow exhaust. 30 x 9.5 Discoverer S/T's on Viper mags. L/R tank. (AWOL) '98 LTD 2.4 SFA, dual battery system. Dobinson suspension, LR tanks, 31" BF mud's.
Real Name: Andy

Mon May 09, 2016 9:53 am

Looking good! :thumbup:

Depending on the size of the speakers, they can be quite heavy .... might cause cracking or even tear out after some lengthy rough road driving. :think:
When your road comes to an end ...... you need a HILUX!.

Image
Image

Life is like a jar of Jalapeño peppers ... what you do today, might burn your ass tomorrow.
Don't take life too seriously ..... no-one gets out alive.
It's not about waiting for storms to pass. It's about learning to dance in the rain.
And be yourself ..... everyone else is taken!

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Knuppel
LR 4WD Full Lockers
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Joined: Sat Aug 29, 2015 2:11 pm
Town: White River
Vehicle: '87 SFA HILUX D/CAB
Real Name: Marius

Mon May 09, 2016 10:13 am

Looking good yes! Are you going to make new gutters also? or does the new skin come with?
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Froll
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Vehicle: 1995 2,4 SFA Hilux,Home made snorkel,Home made front bumper .
Real Name: Roger
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Mon May 09, 2016 10:00 pm

Andy, not too worried about the weight, but more about the sound quality. the fiberglass skin will be about 6 mm thick where the speakers will fit. Worried about having a tinny sound.
Marius, the roof skin does not come with the gutters. I was going to try and bend the gutters from a steel sheet. I often find myself sitting and looking at a problem and get a lot of ideas. I saw a piece of 20 mm square tube lying on the floor and cut it into the gutter shape, it works and looks good. It is about 2mm wider than the original gutter, so I will post those pics when I have cut the tube.

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Froll
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Real Name: Roger
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Sat May 14, 2016 10:22 pm

Did not do any steel work today. Did cast the fiberglass roof shell and started fitting. The weather is quite cool at the moment so the fiberglass took longer to harden than I expected, did not use to much hardener due to the big area to cover. I have to finish this before I can fit the roof skin, as I have to work from the top as well. So I decided to finish this job before I carry on with the steel work. Have decided not to fit the speakers in the roof, because when I measured with the skin in they will come down too far and maybe be in the way when people sit in the back.
Attachments
IMG_0729.jpg
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ChrisF
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Sun May 15, 2016 6:18 am

MOOI !!

Roger het jy oorweeg om n console in te bou in die lining vir die vhf radio ?

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Froll
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Vehicle: 1995 2,4 SFA Hilux,Home made snorkel,Home made front bumper .
Real Name: Roger
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Sun May 15, 2016 9:34 am

Dankie Chris, nee ek wil nie n consol he nie. Wat ek wel gaan inbo is n reverse camera in plek van die spiel. Ek het een present gekry en my canopy het nie vensters in nie, so ek dink dit sal goed werk. Ek weet nie wat se die wet van dit nie, maar ons sal sien.

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ChrisF
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Sun May 15, 2016 10:59 am

AS die wet sukkel kan jy altyd n spiel insit, een van daai wat aan die voorruit vasgom .... nie dat dit deur die canopy kan kyk nie ... maar hoeveel bakkies gaan elke dag deur roadworthy met sulke canopies sonder probleme.

Daar is duisende aflewerings bakkies met daai groot glasvesel canopies waar die middel spiel niks beteken nie ...


so jou reverse kamera is n bonus.


Gaan jy hom permanent laat aan wees, saam met die ignition ? Of net op reverse koppel ?


Met Elders was dit net op reverse. Het n paar keer oorweeg om n ekstra skakelaar in te sit sodat ek dit ook manually kan aansit vir kort tye ... net n paar diodes dat die manual switch dan nie die reverse ligte aktiveer nie.

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Froll
Monster Truck
Monster Truck
Posts: 3281
Joined: Sat Oct 13, 2012 10:13 pm
Town: Vioolsdrift
Vehicle: 1995 2,4 SFA Hilux,Home made snorkel,Home made front bumper .
Real Name: Roger
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Sun May 15, 2016 3:37 pm

Chris, ja dit klink soos n goeie idea om n extra switch in te sit. Maklik genoeg om te kopple met diode in lyn. :thumbup: :thumbup:

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Froll
Monster Truck
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Real Name: Roger
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Sat May 21, 2016 8:01 pm

Today I finished fitting the galvanised plate around the edge of the roof liner. Did a bit of fiberglass work while it was in place. Will remove it when dried enough and complete fiberglass work. Then I can start with the metal work.
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Knuppel
LR 4WD Full Lockers
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Posts: 545
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Town: White River
Vehicle: '87 SFA HILUX D/CAB
Real Name: Marius

Sun May 22, 2016 8:25 am

Maybe you must make two of those skins for the ceiling :D: :P
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Dowe Koos
LR 4WD Full Lockers
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Town: Pretoria
Vehicle: Toyota Buschwagen 2.7 4x4
Real Name: Hennie

Sun May 22, 2016 9:57 am

Hallo Roger, hou jou thread dop van die begin af, moet sê netjiese stuk werk wat jy doen. Sal graag jou eindproduk wil sien.
Ecc 1:9 Wat gewees het, dit sal daar weer wees; en wat gebeur het, dit sal weer gebeur, en daar is glad niks nuuts onder die son nie.

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Froll
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Sun May 22, 2016 11:41 am

Hi Marius, I cannot make two because the mold I made is a throw away one. All I made was a curved roof, I am using the galvanised plate to complete the mold and add strength to it. I will fiberglass the plate in and finish it off. To make a proper mold is a mission as you need the exact sizes or a part to take a copy from and there are no copys to be had. I am making it out of my head as I go along, so hopefully it comes out ok.

Thanks Hennie, to recieve good words helps to motivate a person to do a better job. When a person does a job with no one to see what you are doing you tend to cut some corners, which in the end just gives you more work. I am doing this job with the end result is that I will not have to do it again in my lifetime. When my son inlaw gets the truck one day , it will hopefully last him a long time as well.

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Dadz Toy
Low Range 4WD
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Town: Cape Town
Vehicle: SFA Hilux 4Y EFi $ 95 Series Prado
Real Name: Richard
ORRA Call Sign: HC 286

Sun May 22, 2016 10:16 pm

Excellent work so far!
I shall be following this thread with keen interest!

Keep up the great work!

Rich
Back from the Dead!
I dream of a 3UZ, but my 4Y just keeps going 100%
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Froll
Monster Truck
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Sat May 28, 2016 7:39 pm

Today I welded the steel pieces in and made up the gutter. I welded ok and found the mig welder to be very good. Had to use the grinder to finish the job off. I think it did not come out too bad. Once the roof skin is on I will be able to see how close it is. Will have to fill it in with body putty in a few places, that is the problem with not being able to get hold of replacement posts.
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The Legend
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Town: Kempton Park
Vehicle: 1)1989 Toyota Hilux 2.2 4y EFI D/C 4X4 Full Mikem suspension ,extra long range tank,Duel battery system,31 Bridgestone Duelers 697 A\T FJ 75 front disc with KZTE calipers ,Kurisun PT 8100 two way mobile radio Hi-Lux call sign HC 121
Real Name: Dawie
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Sat May 28, 2016 7:51 pm

Looks very good Rodger.Can,t wait to see the final product. :thumbup:
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pietpetoors
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Sun May 29, 2016 10:36 am

Looks great, for a non-panelbeater you got a lot of guts.
A grinder is an awesome tool, just try to keep the body putty as thin as possible. Not sure what the procedure is but it will make sense to me that one first put some etch primer or something on the metal before one puts the body putty? Cars always rust between the metal and putty which cause the putty to flake.
Only Dead Fish Go With The Flow!
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1999 Hilux 2.7i 4x4 Raider DC. Rear diff-lock, Red Peppor Bull Bar and rock sliders, 31" Cooper ST, Snorkel, Alu-Canopy, VHF Kirisun radio, West Coast Rust, Mikem Rear Suspension, Ball Joint Spacers in front, 25watt LED Spots

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ChrisF
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Sun May 29, 2016 11:33 am

pietpetoors wrote:Looks great, for a non-panelbeater you got a lot of guts.
A grinder is an awesome tool, just try to keep the body putty as thin as possible. Not sure what the procedure is but it will make sense to me that one first put some etch primer or something on the metal before one puts the body putty? Cars always rust between the metal and putty which cause the putty to flake.
Looking at Overhaulin you will note they always strip to baremetal, and immediately put a base coat on. Remember Chip mentioning that the oil on a human's hands is enough to start the rust process ....

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Froll
Monster Truck
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Sun May 29, 2016 12:29 pm

I used a NS1 rust buster which is a rust convertor and primer. I have used it before and it has never given me problems yet, so hoping for the best. I always use an under coat before I use any filler as you can see the places that need to be filled better. As you say I am not a panel beater by trade but I will take on most types of work and learn through my mistakes and by getting advise from someone who knows the job. :thumbup: :thumbup:

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Froll
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Real Name: Roger
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Sat Jun 04, 2016 7:28 pm

No update this weekend. Did my monthly trip to Springbok for month end shopping. What I did do is get my replacement motor that is going in. :thumbup: :thumbup:

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ChrisF
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Sat Jun 04, 2016 8:44 pm

now THAT is some lekka monthly shopping !!

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pietpetoors
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Sat Jun 04, 2016 8:50 pm

What I did do is get my replacement motor that is going in.
and??????
what is that?
Only Dead Fish Go With The Flow!
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1999 Hilux 2.7i 4x4 Raider DC. Rear diff-lock, Red Peppor Bull Bar and rock sliders, 31" Cooper ST, Snorkel, Alu-Canopy, VHF Kirisun radio, West Coast Rust, Mikem Rear Suspension, Ball Joint Spacers in front, 25watt LED Spots

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ChrisF
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Sat Jun 04, 2016 8:56 pm

pietpetoors wrote:
What I did do is get my replacement motor that is going in.
and??????
what is that?
:ttwwp: :ttwwp:

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