The longest build thread ever, at least it seems like it!

[eightydeuce]

Looking forward to seeing that top on there. Awesome work as always Al.

[Kaiserjeeps]

Hi Bill !! Good to see you poke in here. Yep, I hope to get this thing done by mid spring. Or at least wired and driving. They are never done. I have the coolest top on the zone...LOL

[Kaiserjeeps]

This was one of those projects you think will get knocked out quickly. Then you start finding delays. Between the door frame sides and the rear bow, I have 94 holes I have welded up and dressed back. Crazy amount of holes. I kept finding ground down rivets. I got it fixed as good as new.





Onward

[gonz]

Dang, that looked like a sprinkler tube, lol! Your dedication is amazing.

[Flingarrows]

Wow. No more Swiss cheese

[Kaiserjeeps]

I know, was that not something else? I kept finding them and kept turning the TIG welder back on. From what I understand the bows are very difficult to make. The bends wrinkle and fold when people have tried to make them. Glad I was able to save them.

I got the fender skirts on. The inner front grill support too. I need to get the remaining sheet metal painted tan. And put on. I need a windshield washer system. I have several FSJ center dual jet sprayers. I need to figure something out there.

[brute4c]

I used the fsj pieces on mine back when...when
I drilled to put the spray nozzles in the same place as the donor vehicle, if I remember correctly, the drivers side went in the same place but the passenger side had to move to the side of the original position...could be the other way around...its been a long time...but regardless, they worked fine that way...

[Flingarrows]

I know, was that not something else? I kept finding them and kept turning the TIG welder back on. From what I understand the bows are very difficult to make. The bends wrinkle and fold when people have tried to make them. Glad I was able to save them.

I got the fender skirts on. The inner front grill support too. I need to get the remaining sheet metal painted tan. And put on. I need a windshield washer system. I have several FSJ center dual jet sprayers. I need to figure something out there.

When you get that ironed out, please post up. I need something too.

I have the washer tank, but no nozzles yet

[Kaiserjeeps]

I will have a look tomorrow and see if the FSJ single post dual spray head might work. I am pretty sure I have an extra for you George. Hey Jon, did you use what I am describing or did you use two individual spray nozzles in front of each side? The wag or J truck nozzles go dead center just behind the hood. I am not sure they will spread far enough apart for a flat windshield.

[Kaiserjeeps]

The windshield is painted and drying. Lots and lots of work on it. 22 holes got welded up from hard top installs. 24 holes if you include the oversize hole and the one drilled next to it. On the bottom side for the base gasket to cowl seal. I run cross hairs and weld it back up. Then retrace the cross hairs and center punch it for a new correct size hole. There was also a bad rust patch from water sitting there.



Terrible rust and the only real bad spot. I welded every bit of this back. I also ruined a whole tungsten rod from blow back. I hate this type of repair. Grind your tungsten and instantly ruin it.



So the great big plug welds on the windshield frame cause leaks. The big lumps hold the lower gasket off the windshield frame and allow water to get in on the sides of the welds. I decided to grind and sand all of them off and give a flat surface for the gasket to seal against. This is my attempt to stop lower cowl gasket water leaks. Ok everybody can stop laughing now. I will try.
See the welds and gasket lines?



All gone.



A skim coat of putty for a super flat seal surface.



I coated the inside of every cavity with some left over internal frame paint.



Primered and some seam seal where it was needed.



It is done. Now to let it dry for a few days then comes reassembly. I hope the glass goes well. It had better. This glass is thicker than what you can get now. No coffee that day.