2nd Gen 1/4r panel replace

[slacker]

Nick rolled in today for his booked appointment to have his second gen 4Runner 1/4rs installed

got started by pulling the interior out

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[slacker]

got the rest of the interior out , and removed the rear hatch

also removed the drivers flare , and as suspected , it's the same as the passenger side

also , got the rear 1/4r windows removed

ugly job , I wear rubber gloves with cloth gloves over top , soaked in wd40 ..


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[itgogitrev]

I had no idea that the rear quarter windows were held in with those pins. Learn something new every day.

 

[slacker]

I had no idea that the rear quarter windows were held in with those pins. Learn something new every day.

they are bolted in , studs .. with nuts .



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[slacker]

time for some test fitting
take your time .. this will take some time .. I'm about 3 hours total fitting and removing , a little trim here and there , off and on about 10 times , but you want to do this to fit them correctly

and now I'm happy with the fit ... time to fit the window

and happy with this ... I can now move on the the rust repair



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[slacker]

ok so now we have a great fit .. time to fix the rust
first I took a couple of measurements of the piece I would need to cut out . then got my sheet metal , drew the lines , and cut it out .. jig saw works great for these small pieces .

Then with the mini bender , you can put an edge on it .. a piece of 2X4 it counter edge will work as well

and although no one will ever see it , I used my bead roller to put the factory type "dimples" in the metal

and now , I can take these pieces , and use them as my template for cutting the rust out

and now tacked in place I can now prep for the POR15 treatment

POR15 done .. to cure overnight

also .. got the "glue tabs " done to cure overnight as well

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[slacker]

so with the long weekend over , and everything cured , time to make the sides permanent .

We use in our shop , and recommend 3M panel bonder #08115 . not cheep , but in my opinion , it is the best + it is the only product that offers a lifetime warrantee

be very liberal with it .. I use a popsicle stick to spread it out , and make sure I cover all bare metal

installed and clamped

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[slacker]

all done , Customer has picked up , paid , and even booked an appointment for next year , for more stuff .. maybe even a 3.4L engine swap ...
enjoy the pics

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[Beanzermin]

Great work!!

 

[slacker]

Great work!!

thanks ... easy peasy .. most people could do this install them selves , but the thought of "body work" intimidates lots of people


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[Ahlem]

Any chance you have some more mid-stream shots showing the blending of the old and the new seam lines?

 

[slacker]

Any chance you have some more mid-stream shots showing the blending of the old and the new seam lines?

I don't ... and I have been asked this now a couple of times . It's really up to you !! , as I mentioned earlier in this post , FITTING takes some time . this is 1 perfect example . when YOU buy the panel from us , it is "raw" .. YOU need to fit it ..
so as for the rocker area , I take a barrel dremal tool and "thin" this area to mimic the thickness of the original metal , that way , I have a PERFECT fit

We're currently working on some youtube install vids , so it is coming ..



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[Ahlem]

Just curious about how you handled the thickness difference between steel and fiberglass. I've done some extensive work way back when and like the idea of the rust proof option you offer.

 

[slacker]

Just curious about how you handled the thickness difference between steel and fiberglass. I've done some extensive work way back when and like the idea of the rust proof option you offer.

if you read the post above , it will give you an idea on the rocker area .

so as for the rocker area , I take a barrel dremal tool and "thin" this area to mimic the thickness of the original metal , that way , I have a PERFECT fit

We're currently working on some youtube install vids , so it is coming ..
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The areas where it is important to have the same thickness to mimic the steel panel , the fiberglass is "thinned" ..
there are only a few places you need to do this though , but again as above , it does take time


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[88Toy]

Excellent post, Thanks. Its good to know what products work the best and with a 1st gen panel project in the works, this may be useful.

 

[slacker]

Thanks
we have a customer in our shop now from CO ... he has chosen to go with every piece of fiberglass we offer for his first gen 4Runner + the hi clearance version at that ! .. so watch for my posts on that



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