fc ute @lone star body shop

[lonestar395]

The inner tailgate frame was rusted and beat up, it is unlikely we would find something better so the decision was made to fabricate a replacement panel for the damaged lining and TIG weld it into the remaining margins...A complete inner frame could be shaped, however this way results in an effective solution in a shorter time...read less cost.

[waynos]

i've been doing some jedi mind tricks at work recently.......
somehow ive managed to coax stuart and turns into loving fcs
they both have thankfully joined this forum,
so now you will get to see some really awesome build pics,
instead of my crappy phone pics i take now and again.
grab some popcorn,
sit back,and enjoy

[collecta]

I want one of those inner skins 

[FireKraka]

I second collecta I really need one of those come on guys you can't tease us like this and not offer up something

Regards
Neil H

[lonestar395]

I intended to post up more photos last night of the tailgate...for some reason we had no connection, mate said the state of origin footy had something to do with no data?





I will get something up when I get a moment...sorry for teasing Neil

[lonestar395]

Got some more Mileage on the tailgate, coated all the inner pieces with weld-through primer to prevent future rust, fitted and spot-welded all the doubler plates and internal bracing into the frame, welded the replacement inner face into the shell and crimped on the outer skin we had previously wheeled up then trial fitted it to the Ute back with hinges attached to confirm correct fit...

[VAN059]

Great job guys!

[lonestar395]

The lower door frames had some rust repair sections shaped and welded in


 



Wayno has prepared lower door skins, first wheeling the correct shape in, then tipping the edges, which is a critical step to maintain the correct door gaps after installation.
After trial fitting, the skins are tack welded, the tacks planished to restore the correct shape...then TIG welded to complete the join.

[DJ]

Threads like these showing skill in detail are great, thanks for sharing.

[Longman]

Work and skills on display here are almost enough to make a garage hack like me lose faith in my own abilities!  Nice work, keep the pics coming.

[waynos]

Work and skills on display here are almost enough to make a garage hack like me lose faith in my own abilities!  Nice work, keep the pics coming.

dont lose faith just keep refining those abilities.we  are here to inspire you mate

[Longman]

dont lose faith just keep refining those abilities.we  are here to inspire you mate

Thanks Waynos, I think I'll need it. Did a welding course today at a local Men's shed, made me feel a bit more confident!

[waynos]

good on ya .pm me if ya need any advice mate

[lonestar395]

 
We got underbody sealer sprayed under the finished floor areas, and coated with primer.

 

[GMHwagoon]

lonestar 

         can l ask the process you went through on the under floor   

         you started  with bare metal  after doing the repairs
         you said sealer  was it two pack ?
         then primer what type ?
         what are you finishing it with  ?


             thanks greg 
                                                       

         

[59wagon]

Thanks for the pic's. Is that sealer an off the shelf item that you just stick on the end of an air gun?
Cheers, John

[lonestar395]

lonestar  

         can l ask the process you went through on the under floor  

         you started  with bare metal  after doing the repairs
         you said sealer  was it two pack ?
         then primer what type ?
         what are you finishing it with  ?


             thanks greg  
                                                      

          

The process starts with abrasive blasting the floor then coating the areas with epoxy etch primer.

After the etch has set up, brush-on seam sealer is applied to the areas where weld seams or factory overlap joints exist...Sikaflex sealer is also used where it is appropriate to work along a seam with a caulking gun, then smoothing with your finger.

After the sealer has set, the whole area is masked, re-coated with etch primer and after flash time, it is sprayed with the splatter schutz (see photos).

Because the ambient temperature is below 15c, it was left for 2 days before it was re-coated with primer, ready for re-masking for 2K color.





Above image is as it appears just before masking is removed...there is a Ton of work on the rest of the vehicle to be done before it is to be painted, if there is any collateral damage here, it will be detailed and re-primed as necessary.


The Ute has been partly disconnected from the rotisserie to allow the front subframe to be trial fitted and front sheet-metal mounted to it for gap checking and adjustment before preparation for prime/paint





.

There is a 2 Pak splatter called Raptor (TM) that I also use where abrasion resistance is required, it can also be painted with color directly over the product, however it ain't cheap

[waynos]

spent today getting bonnet ,door and guard gaps perfect

[FireKraka]

Hey guys has there been anymore progress on the FC ute.

Regards
Neil H

[lonestar395]

Steve's FC Ute has been retrieved from the paint shop where the inside edges have been painted original body color, we will re-fit the front subframe, hang exterior panels and re-gap and make it a roller so it can be returned to the paint shop for final color on the exterior