HJ45 flatdeck restoration

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diogenese
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HJ45 flatdeck restoration

Postby diogenese » Sun Aug 16, 2015 6:33 am

I'm restoring a HJ45 flatdeck that I bought for spares for me mud truck, it turned out to have so little rust that I couldn't bring myself to break it.
It did have a 3B lashed into it instead of the H so that has come out and will do duty in the other toy :)
The chassis has been sand blasted and epoxy coated after cleaning up the mess of the other engine mounts.
It's down to the last nut and bolt on the body and I have a few repairs to do before getting it painted, that's the only bit I don't want to do myself.
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I have restored cars in the UK many years ago but I am new to tig welding. I need to improve my prep, gas welding was much more forgiving!
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Heath
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Re: HJ45 flatdeck restoration

Postby Heath » Sun Aug 16, 2015 1:20 pm

Wow I wish my project had that much rust in it - LOL

Looks good, I'm not a welders asshole (more of a grinder - LOL) but my MIG work is improving with practice.

Be nice to see another preserved 45 on the road (mine cant be called preserved anymore as it has been......modified).

There are a few places on the web for parts a couple in Aussie that can provide the replacement rubbers if needed for various bits, but be prepared for the price if it is toyota genuine - not cheap.

Good luck!!

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Heath
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Re: HJ45 flatdeck restoration

Postby Heath » Sun Aug 16, 2015 1:22 pm

Just noticed the 70 series side lights on the guards.


Hmmm food for thought for me... although I do have some taiwanese copies of the 40 series ones for my one.

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diogenese
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Re: HJ45 flatdeck restoration

Postby diogenese » Sun Aug 16, 2015 7:11 pm

Heath wrote:Just noticed the 70 series side lights on the guards.


Hmmm food for thought for me... although I do have some taiwanese copies of the 40 series ones for my one.

The lights are normal square ones fitted onto the bonnet sides instead of the guards. They are faded all white! I have got some genuine early round ones from ebay. http://www.ebay.com/itm/351424837384

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Re: HJ45 flatdeck restoration

Postby diogenese » Sun Aug 16, 2015 8:09 pm

I've got the tub welded up, now to start on the other panels. There is nothing too scary but you can see why these rust so bad usually, there is not even any primer on the joints, just bare metal.
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Kampfer
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Re: HJ45 flatdeck restoration

Postby Kampfer » Sun Aug 16, 2015 9:56 pm

Nice I defintly a better base for a Rebuild than what I got. Should be a nice truck when it done.

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diogenese
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Re: HJ45 flatdeck restoration

Postby diogenese » Tue Aug 25, 2015 6:34 pm

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The chassis is back from the sandblasters in a fetching satin black epoxy.

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Re: HJ45 flatdeck restoration

Postby Kampfer » Tue Aug 25, 2015 7:44 pm

Looking good. A lot better than my new chassis. What year is your truck? I'm trying to figure out a rough idea of how old my replacement chassis is.

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diogenese
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Re: HJ45 flatdeck restoration

Postby diogenese » Tue Aug 25, 2015 7:55 pm

It's a 1976 aussi import. I have a '79 NZ truck and the chassis looks identical.
I have snuck in two chassis repairs before getting it coated, the weld above the rear cross tube was cracked and a bit of rust where the chassis kick up starts.

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Re: HJ45 flatdeck restoration

Postby Kampfer » Wed Aug 26, 2015 9:24 pm

Interesting, It must of been about 78 when they changed the Chassis design. My 84 has completely different mounts for everything. Not much help in IDing mine though lol. My original Chassis has cut short and and is pealing apart with Rust, And my new one I've imported from Aussie has the wrong mounts and a few good cracks around the shock mounts and the rear cross tube like yours. i think I counted 7 all up and a few dodge repairs. Still an easier fix than my original just more of a pain than I was after.

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diogenese
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Re: HJ45 flatdeck restoration

Postby diogenese » Wed Aug 26, 2015 10:32 pm

I have a rotten bj42 in my collection and that is an 80something vintage and the mounts for the B motor and gearbox are completely different on that. They are different again for the F motor. Is your replacement chassis for an H?

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Re: HJ45 flatdeck restoration

Postby Kampfer » Thu Aug 27, 2015 4:51 pm

Na its an Early FJ45. Its got the same Gearbox mount as your but no engine mounts. And the body mounts are all different. Fortunately they are the only good parts on my original Chassis, it shouldn't be to much of a hassle to swap them over.

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smurf182
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Re: HJ45 flatdeck restoration

Postby smurf182 » Thu Aug 27, 2015 7:15 pm

Always good to see another old Cruiser rescued from a rusty demise!

Keep the pics coming

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diogenese
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Re: HJ45 flatdeck restoration

Postby diogenese » Sat Aug 29, 2015 10:04 pm

I've thrown the engine back in, fitted some new shocks and brake hoses.
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These are the engine mounts
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Has anyone seen any free wheel hubs like this before?
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All the green bits have gone to the blasters and painters. I still have rust repairs to do on the roof and rear windows but they will get done after blasting to get all the rust out.

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Heath
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Re: HJ45 flatdeck restoration

Postby Heath » Sat Aug 29, 2015 10:30 pm

good idea getting a clean view of what you have hidden under the paint (and bog maybe).

I spent ages struggling to cut out 3 inches in height with what I thought was my ineptitude (some of it was me) but discovered that the bits I had been trying to weld were riddled with rust. I ended up cutting the bottom 6 inches of the back of the cab upper (bit with windows) and rebuilding the base.

I get the paint/bog/rust blasted off before I start now...

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Re: HJ45 flatdeck restoration

Postby diogenese » Sat Aug 29, 2015 10:41 pm

Yes it's the bit with the rear windows that is the worst bit on the truck. I'm going to have to make the upper triangle box section along most of the frame :(
There has been no bog, some painted over aluminium tape, but no bog!

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drive it ...
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Re: HJ45 flatdeck restoration

Postby drive it ... » Sun Aug 30, 2015 8:56 am

Has anyone seen any free wheel hubs like this before?


Now your rebuild is heading to the dark side - I googled "selectro free wheel hubs" and got crazy poms debating if the bolts were BSF or whitworth ( the thread originator was hammering metric sockets on Ha)

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Heath
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Re: HJ45 flatdeck restoration

Postby Heath » Sun Aug 30, 2015 1:29 pm

diogenese wrote:Yes it's the bit with the rear windows that is the worst bit on the truck. I'm going to have to make the upper triangle box section along most of the frame :(
There has been no bog, some painted over aluminium tape, but no bog!


Mine was swiss cheese and looked like the guy was sponsored by a filler company. He did a fantastic job though as it wasnt easy to spot until the blaster got into it.

Seems the bits where panels bolt together are almost devoid of paint or protection and they seem to be susceptible to water pooling. Might use some windscreen sealant to glue things watertight when the time comes.

Where abouts are you (Im in Chch)? I have a spare rear frame that I need the glass out of. The bottom is completely buggered but the top might be okay for your needs. Having said that folding up some new steel might be a less painful way of doing things.

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Re: HJ45 flatdeck restoration

Postby diogenese » Sun Aug 30, 2015 1:50 pm

Hello Heath, I am not too far away in Temuka. I have a spare cab top half that I kept from my donor truck that has some metal left in it but the fabrication of new bits is part of the fun!
I'm not sure yet what to seal the joints with yet but all my bits are getting painted individualy so the rust should be less of a problem. I will have to touch in the seals by hand after assembly to get a colour match and I'm not looking forward to that :(
How's the rod coming along, there hasn't been an update for ages :wink:

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Heath
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Re: HJ45 flatdeck restoration

Postby Heath » Sun Aug 30, 2015 3:38 pm

Not much happening to be honest. Lack of funding, a cold garage and exams st polytech means its sitting gathering dust, but the planning side is still moving. I'm buying little bits here and there while the dollar isnt too bad (mainly painting gear) getting ready for another push forwards.

Got to take the cab off again to fabricate handbrake mounts and run the new cables to the ford 9 inch drums and clean up the firewall a little and fix a few dents in the body.... it just goes on and on... LOL

I should chuck a post up I guess showing how little i have done.

Ive got to admit getting a flat bit of steel and creating a part from it is pretty satisfying.

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Re: HJ45 flatdeck restoration

Postby diogenese » Sun Aug 30, 2015 10:48 pm

I've spent the whole day cleaning and painting black brackets and bits. It was too dull to take a picture of.
I mentioned before that I don't like painting :)

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Re: HJ45 flatdeck restoration

Postby diogenese » Wed Sep 02, 2015 8:20 pm

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I've made new brake pipes, mainly because the old ones had been adjusted too many times and were very hard.
A few more bit and pieces have gone on but I'll be back to welding again soon.

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Re: HJ45 flatdeck restoration

Postby diogenese » Wed Sep 02, 2015 8:26 pm

Does anyone recognise this little panel? I've cleaned and painted it but I can't remember where it came from!
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diogenese
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Re: HJ45 flatdeck restoration

Postby diogenese » Sun Sep 20, 2015 6:03 pm

I've finished up with the welding now, just got to get the last two panels back to the blaster and start to get stuff painted.
I have got a few pics of the repairs to the window panel.
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One corner of the roof was full of bog, I had it blasted so I knew how bad it was going to be. Pretty good was the answer, only two patches needed.
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diogenese
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Re: HJ45 flatdeck restoration

Postby diogenese » Sun Sep 20, 2015 6:07 pm

I will need a skim of filler over the weld but at least I know there is no more rust :) I have resealed the seam around the gutter too.
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The tub has been blasted and is going to get some paint next week. Top coat will have to wait till the other panels are ready.
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Heath
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Re: HJ45 flatdeck restoration

Postby Heath » Sun Sep 20, 2015 6:16 pm

Nice project ute you have tucked away there!!!

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diogenese
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Re: HJ45 flatdeck restoration

Postby diogenese » Sun Sep 20, 2015 6:23 pm

Heath wrote:Nice project ute you have tucked away there!!!


Unfortunately that's not mine, it's just in the same paint shop :(

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diogenese
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Re: HJ45 flatdeck restoration

Postby diogenese » Sun Oct 04, 2015 7:44 am

My tub has been painted, the rest of the panels will be done later.
I can now fill up the cavities with fish oil and fit it to the frame and pretty much get the beast running.
The rest of the parts will get painted later, apparently insurance work pays a higher rate than I am ;)
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Heath
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Re: HJ45 flatdeck restoration

Postby Heath » Sun Oct 04, 2015 3:13 pm

Nice!!

I am jealous as fk!!

Good work.

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diogenese
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Re: HJ45 flatdeck restoration

Postby diogenese » Sat Oct 10, 2015 4:26 pm

Tub is back on :) But I had a nightmare with undersealing the underneath. I used some aerosol Duplicolour rubberised undercoat which didn't set and had water in it. I had to scrape it all off and wirebrush it all and do it over again with a different product.
https://www.dropbox.com/s/k728jm5lwadt1 ... l.mp4?dl=0
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