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Old 10-10-2019, 12:52 PM #46
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Quote:
Originally Posted by brillo_76 View Post
This is my hobby.

I am just showing DIY that you can fix it yourself. Saving $$ and having the satisfaction of you did it. Some folks pull the bodys off. Some folks put other frames under them. You can do it that way if you wish and have the room and the tools to do so. :]

As for the frames repair, The entire reason I do this is to improve my welding skills. Anyone can weld in the standard position. Learning how to weld upside down and on non clean new steel takes time.

If you take you frame out and sandblast it. You still need to cut the rot out and get rid of oxide in the inside of the frame along with sealing the frame holes. So plating the inside with a new bottom would accomplish this. Plus if you ever need to put new body mounts on you have steel to weld to as the plates are inside the frame and easy to weld to.

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Fair enough, I'm not trying to critique your methods either.

If you're having fun and etc. that's great just thought it would be easier to pull the whole thing apart, inspect it and fix it all in one shot. I'm sort of lazy, so I always want to take the easy way out.
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Old 10-10-2019, 07:42 PM #47
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Quote:
Originally Posted by APhelps View Post
Fair enough, I'm not trying to critique your methods either.

If you're having fun and etc. that's great just thought it would be easier to pull the whole thing apart, inspect it and fix it all in one shot. I'm sort of lazy, so I always want to take the easy way out.
Oh you have valid points. That is defiantly another way to do it. However, the entire rig would have to be pulled apart and folks would have to have places to store everything. My methods, you can actually do the frame in sections and even do the rockers one at a time. Plus I am currently driving this rocker rig and I already have 2 in my garage getting Frame repairs.. So I am out of room.. I even have to weld these rockers in outside...;-)
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Old 10-10-2019, 10:33 PM #48
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Quote:
Originally Posted by dogtail View Post
Heres the one I'm chopping for parts, 2000 5spd with 230K. It was on the cusp of repairable or parts rig, I took it over the edge. Frame was repaired, but I wasn't a fan of the work. Its a shame the PO let it go, its a nice looking rig.
Yup, some of them are on that edge. If your selling parts, PM me. I could use those 2 front fender flares for another one of my fleet.

Thanks for Sharing Dogtail.. :-)
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2001 4X4 V6 Sport Green 4 Runner (01 Green Sport)
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Old 10-12-2019, 06:03 PM #49
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Finally got the passenger rocker welded back on. Well the top of it anyhow. I ran out of welding gas. Anyhow getting closer to getting that area sealed up again..

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Old 10-13-2019, 06:14 PM #50
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Rebuilt the front corner used the piece that I cut off the rocker to weld the 1 x 2 into place. Then welded a homemade angle out of 20 gauge over the both. Reboxed the front with 20 gauge and saved the front factory hole for spraying the inner rocker. The bondo is only to seal the rocker. I smooth that up and paint it but at least it's all sealed up in the front now.

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1997 4X4 V6 5 Speed Sr5 4 Runner (97 5 speed )
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2001 4X4 V6 Sport Green 4 Runner (01 Green Sport)
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Old 10-15-2019, 08:17 PM #51
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Rebuilt the rear fender well using 20 gauge steel. I even used seam sealer and painted it with epoxy paint. It's not perfect as I never claimed to be a body man but the hole is sealed up along with the rear rocker so I happy with that.

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1997 4X4 V6 5 Speed Sr5 4 Runner (97 5 speed )
1997 4X4 V6 Red limited 4 Runner (97 Limited)
1998 4X4 V6 Sr5 Red 4 Runner (98 Tetanus1 )
1998 4X4 V6 Sr5 Silver 4 Runner (98 Tetanus2)
2001 4X4 V6 Sport Green 4 Runner (01 Green Sport)
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Old 10-19-2019, 08:04 PM #52
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Starting fixing the drivers side. I started with the dog leg. When they get this rotted. You be fixing the inner fender well as well. Toyota used very thin steel in the inner fender were the inner rockers end You can see how my passenger side was rotted.

I puddy screen a puddy just to seal the inner fender off. Then I weld the dog legs on.

I will add the photo of the welded on dog leg tommorrow. I ran out of daylight for a good photo of it

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1997 4X4 V6 5 Speed Sr5 4 Runner (97 5 speed )
1997 4X4 V6 Red limited 4 Runner (97 Limited)
1998 4X4 V6 Sr5 Red 4 Runner (98 Tetanus1 )
1998 4X4 V6 Sr5 Silver 4 Runner (98 Tetanus2)
2001 4X4 V6 Sport Green 4 Runner (01 Green Sport)
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Old 10-20-2019, 09:34 PM #53
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Made some progress fixing the dogleg and inner fender. Got the driver side rear fender well resealed up.

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1997 4X4 V6 5 Speed Sr5 4 Runner (97 5 speed )
1997 4X4 V6 Red limited 4 Runner (97 Limited)
1998 4X4 V6 Sr5 Red 4 Runner (98 Tetanus1 )
1998 4X4 V6 Sr5 Silver 4 Runner (98 Tetanus2)
2001 4X4 V6 Sport Green 4 Runner (01 Green Sport)
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Old 10-20-2019, 09:37 PM #54
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Then I had to deal with my surprise project. Upper control arm broke. Glad a had a usable spare. Got that switched out and ready to roll down the road tommorrow.

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1997 4X4 V6 5 Speed Sr5 4 Runner (97 5 speed )
1997 4X4 V6 Red limited 4 Runner (97 Limited)
1998 4X4 V6 Sr5 Red 4 Runner (98 Tetanus1 )
1998 4X4 V6 Sr5 Silver 4 Runner (98 Tetanus2)
2001 4X4 V6 Sport Green 4 Runner (01 Green Sport)
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Old 10-24-2019, 11:43 AM #55
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I had to switch to the 01 sport as my wife needs a garage bay for winter. I had to ripped down to the timing belt for inspection as my rad was junk. So the last 2 days, I put it all back together. New Radiator with Toyota coolant. This one had the rear inside frame arches out and a destroyed ring and pinion gears. So I had a rust free rear end shipped in. Put a hitch on it. 3 new belts and assembled it enough to move it around drove it to its winter garage. I am glad just be able move it around.

This is the frame that has POR 15 /KBS seal painted on after I fixed the frame bad spots. Its 90% painted underneath and only has the engine section to do. Been in my one garage bay for 3 to 4 years. As I hobby repair the frames and slowly.

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1997 4X4 V6 5 Speed Sr5 4 Runner (97 5 speed )
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1998 4X4 V6 Sr5 Red 4 Runner (98 Tetanus1 )
1998 4X4 V6 Sr5 Silver 4 Runner (98 Tetanus2)
2001 4X4 V6 Sport Green 4 Runner (01 Green Sport)
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Old 11-03-2019, 10:01 PM #56
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Went back to good old Tetanus 1and rebuilt her drivers inner rocker. I cut the old inner rocker about 3/8 to 1/2 down from floor level. Then welded 4 inch strips of 20 gauge in to rebuild it. As the center support to the front of the rocker was ate by salt. I cut it out as well. Once the inner rocker been welded in and seam sealed. I use a 1 in x 2 in rectangular tube to weld a 3 body mounts to it. Then cut the outer rocker to fit. I cut this one to fit before installing the rectangular tube. You can see I removed the top pinch weld from the rocker. I didn't want to increase the size of the upper pinch weld plus it seems I can get a better fix with it missing. Here are some photos so far. It seems I need to take photos of the inner rocker sealed and painted:]

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1997 4X4 V6 5 Speed Sr5 4 Runner (97 5 speed )
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1998 4X4 V6 Sr5 Silver 4 Runner (98 Tetanus2)
2001 4X4 V6 Sport Green 4 Runner (01 Green Sport)
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Old 11-04-2019, 11:08 AM #57
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Photos of the homemade inner rocker. I am not a professional autobody man. Also, I am sure there are 5 ways to do this. This is just how I did it. Next will be the rectangular tube weld on. Then lastly the outer rocker.

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1997 4X4 V6 5 Speed Sr5 4 Runner (97 5 speed )
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2001 4X4 V6 Sport Green 4 Runner (01 Green Sport)
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Old 11-05-2019, 12:32 PM #58
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Did get the driver side rocker half welded on.

I would do a few things differently.

1). Put the dog leg on last.
2). I would pop rivit the rocker down first then weld it in. Once welded on drill and fill the pop rivets.


Cutting the inner rocker about 1/4 to a 1/2 down. Does seem to work well. I welded the inside and seam sealed both sides of that inner rocker.


The 1◊2 rectangler tube. Seems to do a decent job tying the 3 body mounts together. As all my internal structural steel was pretty much gone.

I used the rocker pieces I cut off to weld and strengthen that rectangular tube.

That was my first set of rockers. So I didn't do horrible. Could have went better probably. I know would have been a lot better if the inner rocker is savable.

I need to clean up the welds and smooth with a little putty yet. Then I will paint the rockers red again


Not sure how gluing these on would work. If I went that route the metal has to all be bare. I would fit it a few times. Then drill pop rivit holes. Then use them to line it up.
Use the pop rivits as the vicing holders. Then probably just light puddy them over.



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1997 4X4 V6 5 Speed Sr5 4 Runner (97 5 speed )
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1998 4X4 V6 Sr5 Silver 4 Runner (98 Tetanus2)
2001 4X4 V6 Sport Green 4 Runner (01 Green Sport)
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Old 11-10-2019, 01:49 AM #59
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Passenger side bottom completely welded on now. I did a drill and fill with it using a 1/4 inch drill bit. Didn't turn out too bad at all considering I started with very little metal left

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1997 4X4 V6 5 Speed Sr5 4 Runner (97 5 speed )
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Old 11-13-2019, 01:47 AM #60
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Making progress sanding down the rockers. Being I am currently driving this one. I have to re primer every time I am done for the night. I am getting closer. Looking alot better

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1997 4X4 V6 Red limited 4 Runner (97 Limited)
1998 4X4 V6 Sr5 Red 4 Runner (98 Tetanus1 )
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2001 4X4 V6 Sport Green 4 Runner (01 Green Sport)
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