Outer Limits 4x4 Board

It is about time to fix the lower quaters on my FJ62 and I want to chop and fold them but have no idea on how to go about it. The pic shows where I want the bottom (the other side is not much better) and talking to a couple of guys they tell me to unpick the seam, cut from the inner and use the outer to bend over and form the bottom.

Sounds good but how the hell do I do it??? This is going to be very tight on the fuel filler side (due to the filler pipe) and there is also the plastic emission control cell (although I think I can loose this due to the engine conversion to diesel). Does the body have to come off to do this? Can an angle grinder be used? How long will it take (the 4b is my dd)?

I'd cut the inner and outer about 15-20mm below the blue line, then cut vertical slots up to the line (about 25-40mm apart), and fold in the 15-20mm excess. Get some sheet steel (or even plastic), cut it to shape and push it into the gap (so it sits on top of the folded in edge). A few pop-rivets or tec screws and copious amounts of sikaflex and your done.

Of course you'll have to try and straighten out some of those 'modified lines' you've made.

Wouldn't bother trying to use all that excess below the blue line to make the bottom, it'd be too hard to fold neatly.

-Stu

p.s. i'm a hack

best way to do it i have found is cut it 5mm below the line all around.

grab some cheap nasty pliers (normal wide type not needle type) and round one side of the jaw (smooth the edges so its not a sharp edge) then fold the 5mm lip with those (sharp edge to the outside of panel, round edge to the inside of the fold) this eliminates the need for nasty slotting or Ving of the folded lip.

you will be able to fold them 80 to 90 degrees being in a tight place with little to no panel beating to finish off the folds.

once bent make a cardboard template that sits just in the middle of the 5mm fold then mark it to steal and cut out to suit. if you have a mig set it to low and weld all around the join, if not sika works well. make sure if it has a drain hole that you also cut one into the new panel.

cheers mark

id agree with mud4b, i'm in the process of doing mine on the mav atm.
I cut about 20mm below the mark i made and then used some pliers to
bend it around. I haven't made the base plate as im still deciding what to do with the wheel arch.

I have taken a few pictures have a look here, may be of some help

http://cars4life.multiply.com/photos/al ... ies_read=8