Daihatsu Fourtrak Project - Rust don’t live here anymore

[mercedade]

Unreal amount of work!

[Spurious]

Love Fourtraks. 

Also love your welding skillz. That's a lot of work. 

 

[rickvw72]

Finished a chunk today, which is a great feeling.

drivers rear inner arch, tied it all together and welded all the repairs both sides, snd joined it to the body mount.

slapped some primer on. Where the peach paint is here is basically new metal. And the grey. So basically it’s 80 percent new in here. 
my home made spring panel from an age ago, this was the first work I did here.

Early pic of this inner arch, 

now looking better and far more steel these days.

the outer sill. This has had a big bit of box welded in. Couldn’t stand how crap it looks, so a quick poke...

the inner sill where the box section is welded to.

Out it all comes.

inner sills are better than I expected, first time I’ve used the words “better than I expected, bodywork and Fourtrak” in the same sentence.

inside area was treated to a skim of filler. This will make it smoother before paint goes on, and I can get good access here now to tidy this up. 
 

Next time round the sills will be repaired, and new outer sills put on. Then I can close the last holes, prime it all, and seal it up. Can’t wait to start priming all areas the same colour, it’s gonna transform how it looks. 

[rickvw72]

Sills time.

Originally this had an inner sill, middle strengthening panel and an outer sill. Some time later a “repair “ was made, and a lump of box section welded in.

Nice work. I lifted this up with my two poster on these sills some time ago, more crunching than a crisp eating competition occurred.

So I cut out the box section.Heavy box section removed. Existing Strengthening panel is neither strengthening or a panel, or existing in any way at all.

So, overall this should be roughly 140cms, the length of the sill. The rearmost couple of feet atre very rough.

The floor above the inner sill. Sound deadening patch was not for sound deadening, but the only rigidity of the floor.

The inner sill rear section lopped out. And the ever increasing in size flint stone floor option.

Wow! Took about 20 mins of tweaking to get the sill hanging in the right place. Tech screwed this on, to get an idea of the shape the inner sill should be. 
 

Cut back out all the rust inside before. About 50 percent of the inner sills out complete. The other 50 percent about the bottom 2 inch is cut out.

Couldn’t resist dropping on the arch cover and bumper. Looks almost complete, and in my eyes the sills shape transforms the side of this. Also reminds me how much of this work won’t be seen in the end!

Spent the rest of today making bits for the inner sill. Gonna tack these on with the new outer in place, then remove outer, seam weld inner repairs, make and fit strengthening panel/ mid sill, paint it all and inside the new outer, before fitting up the new outer and welding it on... then finish off the inner arch..... then weld the now about two foot square hole in the floor up.

Nearly done I reckon.

[Tickman]

Excellent work still going on.

 

[St.Jude]

You are my future! Quite right though, there is something a bit annoying about going to these lengths only for a bit of plastic trim to cover it all up.

I have questions though, and I apologise if these have been asked:

1) what's the peach coloured stuff you're using?

2) do you filler then primer the new stuff? Or do you primer then filler?

3) on the arches where you've welded, are you going to put some seam sealer on it?

4) what are you going to use for the arches to protect them?

I'm interested in the last two really, as I've got it in my head that the best thing to do is to slather on some bitumous isopon underseal stuff I've got in a tin, given how exposed to the harshness of driving they are.

[rickvw72]

On 6/15/2021 at 11:54 AM, St.Jude said:

1) what's the peach coloured stuff you're using?

2) do you filler then primer the new stuff? Or do you primer then filler?

3) on the arches where you've welded, are you going to put some seam sealer on it?

4) what are you going to use for the arches to protect them?

Okay, what works for me-

1. Unknown age hammerite rust paint. Found it in my garage and the tin was easily 20 years old, no longer available as is all good hammerite. It’s almost ran out, so I’ll be moving on to summat else soon.

2. I filler onto the steel, if an area where it’s gonna flex a bit I’ll skim seams with fibreglass filler first, this cuts down on the amount of filler used to finish too. Once done I’ll prime it. This for the top side of a car, underside I go weld, paint weld seam with very good paint, seam sealer, paint again, and maybe a top layer such as Raptor, Shultz or stone chip. I’ll probably do the Fourtrak under side with epoxy mastic, probably Jotun brand. The ouside I’ll do with upol 2k high build, but I am set for two pack spraying.

3. Once a chunk is welded, I’ll seam seal it. Gonna probably go like this In the arches. Remove old crap, clean, grind back and finish welds. Rust killer (bolt hamber hydrate 80) where needed, one coat epoxy, seam seal, another epoxy coat. Undecided whether to overcoat, as think painted underside maybe easier to jet wash clean. Considering Raptor to finish, but not decided yet.

4. Rust killer stuff, seam sealer, 2coats epoxy, maybe raptor.

Much of the underside of the Dai-rot-su is surface rusty, so I’m aiming to kill the rust, seal it up and make it east to maintain. 
 

Welding patches to an old motor, I’d prime and seal welds, paint then a coat of 3m Shultz, I’m probably going further with this rusty knacker than a sane person should. 

[rickvw72]

Another day, another 7000 miles of MiG wire sacrificed to the gods of rusty Japanese steel.

Inner sills then...

Original is spanked

Folded some strips to length and blobbed them on

With a coat of zinc primer, the inner sills started to come together

Strengthening panel at the bottom of the quarter panel. This was not even attached to the box section I chopped off

No Now I could attach the outer to some steel, so I cut it to size.

Fitting well in the door shut area 

the hole to close up in the under arch, but shows the three sill layers together. Most the metal in this pic has never been in a Daihatsu factory.

New sill will fit lovely. Gonna butt weld it, so hopefully should look nice and neat. 
Progress is good, but may slow a little. Partners Civic gearbox is crying enough and the Mk2 Golf is clonking over bumps, and has a months MoT.  Good job it’s holiday time soon! 

[rickvw72]

Rusty old nail update.

Been a bit busy on a few other of the fleet last few weeks, partners Civic had a gearbox and clutch change, Old Golfs needs an MoT and also there’s a rusty vw camper  in the unit next to the beast, so I’ve renamed a corner of the workshop “the bay of decay”.

Works continuing in the rear arch, but not much photo worthy to add. As you can see, it’s still raining rust underneath, and it’s not been outside in moisture for about two years. 

[ChinaTom]

There are still a few of these knocking about amongst the farming community- this one is a regular appearance on market day

 

 

[rickvw72]

Whisper it quietly, but I think the drivers side is done!

First order of business is to close up the inner rear arch.

Made this up, and welded it all in. Outer arch cover is on here too, fits nice and covers so much of the work done.

Inside, the rear bulkhead (which I had to make loads of previously) needed to be joined to the floor.

Had to fabricate and fit a floor crossmember, which is fitted to the inner sills (which I made too).

Ive renamed it a DaiRicksu now, as it’s basically coachbuilt in this area.

Welded a big chunk of floor in. Had to repair and fit the rear seat support bracket, under the black panel that takes the seat base. Ground back and zinc primed it.

Terrible pic of underside. Lots of new steel here, needs a tidy, prime and seal up. This is taken under the door area, looking back at the front of the rear wheel. 
It’s had some bloody welding, this old crate!

I do still need to weld the outer sill on, which means it’s not 100 percent done this side, but all fabrication is done this side I reckon. I’m also fairly sure the other side is better to start with, so tune in next time to share my disappointment when I realise it’s a complete kipper!

[Minimad5]

Brilliant work 😎

The members of this forum have stepped up the game recently, with threads like this, the Morris Minor/ Volvos etc all getting some serious fettle. 

P.s:

Some lovely fabrication & welding on display.

[rickvw72]

Thanks for the positive comments all, this type of works a slog at times and it’s nice folk are interested. The internet is really full of weird folk!

Passenger floor then…

This is under the seat. There’s a nice big patch here (white bit) this was welded to ever bracket and strengthened going.

Inside the arch. All been repaired in the past by covering up the rust. Think the last welder sprayed his steel with salt water before tacking it in.

Chopped a load of crap out, and there was not a lot left.Piles of rubbish that fell out or off. Cut the box section sill off with an air chisel, which vibrated all manner of rust and crap loose.
concours repair to the sill from the past. Looked great, and for bonus points all the rust was still there, so it was rusting merrily.

I improved the look of this by cutting it off and feeding it to the skip.

mmm, there’s a bit too much fresh air in this pic.

This is the inner sill and floor pan.

Well it would be if there was any left.

Remember I said this side was better?

I was wrong.

Its a kipper, confirmed.

 

[sdkrc]

Brilliant work and cracking thread. You're probably one of a handful of people who would put in the mountains of effort to save a car like this and keep UK roads interesting.

These were THE culchie Irish farmer's choice back in my day. I spent many hours in the back of these along with a mental dog being driven around obscure country roads in South west Ireland. Noisy as F is what I remember

[rickvw72]

Had a good few hours today.

Started to reconstruct the missing nearside bodywork.

This should be a picture of a Fourtrak sill and floor. 

There is a lack of steel on display.

Not sure it looks better inside.

Started on the inner sill right at the back. Approx 2 foot long this piece.

With the very top of the inner sill in, I made the rest of the inner sill. 
My eBay outer sill was trimmed up and screwed on and off several thousand times. 
With the very rear done, I moved onto the mid section. This was fitted to the outer sill shape. 

The total lack of any original Daihatsu shape on this means most repair sections are free hand.

Made and fitted a floor cross member on this too - it’s whet the earth clamps attached in the second picture.

Outer sill hanging on. The shape looks excellent in my opinion.

The very rear of the sill.

Most of the bodywork here’s never been to Japan.

Looking much nicer than the crap box section bodge.

BEFORE: crap

DURING: looking good.

Tune in next time to get none of the questions your probably thinking answered.

Such as: Will he ever stop welding the old shit box? Why is he bothering? Does Daihatsu plastic also rust? Is he ever gonna look further forward than the doors, under the front arches?

Im dealing with the front end by pretending it’s fine.

[warch]

This is excellent and well worth doing. Fourtraks are really good utility off roaders and were never really replaced when production ended. There are a few really buggered looking but serviceable Fourtraks still serving on hill farms up the other end of the valley from my place. 
 

 

[rickvw72]

Made some more progress on this today.

passenger side inner sill finished and zinc primed.

floor support piece fully welded to sill.Then I moved onto making bits for the floor. This is to go under rear seat area.

Floor section welded in, mig welded, and plug welded down to the top of the inner sill.

The floor patch above runs from the rear third of door, to the floor strengthener in the pics before, the under seat section goes on top of it all.

It nearly floats!, just the inner arch to make and repair, and weld on both outer sills. (They are fitted, just need welding on)

The light at the end of the tunnels getting closer!

 

[rickvw72]

Threads due a proper update, but I’ve wrapped up the floors, refiffed the back seat mounts, and closed up the rear inner arch bits left to do.

Had a few hours on it Saturday and the passenger sill is now on.

All the inner arch is complete this side now too, as are the floors. Unless I uncover more, I call the passenger side done! 
 

quick time line:

before

 

during.

After.

With this done, I put all its wheels on and dropped it on the ground, for the first in a while.

Most the rear floors look like this now

Needs a good clean up inside and out, and hopefully I’ll get the other sill on Saturday. 

[Metal Guru]

I had a 2.8 TDL from new in 1995 until 2000. It wasn’t a bad drive , certainly better than the equivalent Land Rover.

Last drove one in 2014 on a friend’s farm a scrapper without wings or doors, which we christened the “ Fourtrak Superlegerra”.

[rickvw72]

Busy now prepping up the other outer sill before welding it on.

drilled across the bottom flange for the plug welds.

punched the ones across the top flange. (Sills upside down in the pic)Couple of coats of zinc paint. I’m gonna inject the sills with Bilt Hamber Dynax wax after paint.

 The inner sill. I reckon I made a better job of this on the other side. Gonna redo the bottom flange here I reckon. More zinc paint in here.

Whilst the primer dried, I cleaned up around and inside the old beast.

Four dustpans of crap swept out, and a quick hoover later.

waved a torch around underneath it to look for more holes. Found three, this being most obvious.

List of welding jobs left

1. Offside inner sill bottom flange - make and fit

2. fit offside outer sill

3. three holes in floorpan

4. front crossmember behind radiator

5. Exhaust brackets, hangers and cable mounts underneath. 
 

Once done and painted, mechanical jobs are gearbox oil leak, new clutch, fit remaining rear bushes, New brake pipes and lines, new fuel pipes, new rear shocks and new exhaust. 
Not much then!

 

 

 

[rickvw72]

This might be the uks only Fourtrak with two 100 percent steel sills now.

This was how I’d left the inner after repairing it a few months ago.

I wasn’t happy with the bottom flange, so rejigged it with a proper flange.This fitted the outer sill much more cleaner.

This pic shows some of the many bits stuck together to strengthen the sill and floors. Lots of weld! 
Then it was time to butt weld the sill on. This is along the rear quarter.

Inside the door, front edge.

Used a jack to push up the bottom a touch, to enable the plug welds to be done.

Plugged along the bottom.

ground the welds at the front and primed it.

Same for the rear quarter.

All this messing about means sills of steel!

 

She’s a beauty. (In my eyes anyway!)

[Spurious]

Top welding. Never mind the sills, it's probably going to be the most solid Fourtrak out there. Top welding. 

[rickvw72]

Cheers for all the positive comments!

Thought this would be an interesting old car to post about here, as to me, the threads about stuff being bought back are the best.

 

[rickvw72]

Probably end of year update, although I’ll try to sneak another couple of hours in before new year.

Finished of the inner wheel arch to sill join

Tiny bit of weld is where the floor, inner arch and body mount but join. This is strong now! 
 

Also been finishing off the filler work on the arches, both sides.

None of this seen. I don’t like to remind myself often.

Also tidying up, derusting, and rust treating the inner arches as I go. Been using Bilt Hamber rust converter, and it’s great stuff.

As I guess this is the last post this year, I’ve added a montage of Daihatsu crap piles, sort of a greatest shits compilation:

wicked awesome piece of floor and inner arch.

part of the rear wing. Surrounded by mud. Which fell out of the bodywork

the wonderous sill. 
more rust and mud. Some poo too. And some Fourtrak structural strength

Nastycrispy

Been a crispy year in Daihatsu world.

[MJK 24]

That NS sill has been refusing to soldier for quite a while!

[rickvw72]

Changed from snorting filler and rust dust today, and started on the solvents.

Been filling for a while on these arches, which are a free hand patchwork of metal pieces.

Other side. Also made the bodywork that sits under the bumpers.

Filler flatted down…

The other side..

Passenger rear. Jotun Epoxy mastic paint can be seen on the chassis and inner arch. I painted this on last week, now it’s hard enough to seam seal.

More plates than a Greek restaurant 

Masking applied. I’m still crap at masking up.

Masking the other side too. Cos I hate myself

Painted! With an aerosol.

looking less patchwork

Massive motivation boost here

The other side.

Been using Hycote brand aerosols, both here and with the zinc primer I’ve used on this car. Really impressed, covers well and easy to use.

Inch by inch it’s getting there! 

[rickvw72]

Fresh from the massive morale boosting primer going on, I decided to chuck the old rust bucket on the lift to wrap up some jobs in comfort.

solid enough to lift!!

The Fourtrak can fly!

Off came the wheels

Been dealing with the front condition of this thing by pretending it’s fine so far…

 

[rickvw72]

Let’s have a look then at the front…

nice. 
cute face

bumper and grille off. Around the steering box areas looking a bit rough.

Tide mark of dirt is telling!

off with the wings to get a better look

Front panel un bolts. The steering box and chassis is fine, but the area of the front panel fell to bits.

Front of chassis is very good.

Front of Fourtrak is looking a bit sparse at present.

My partner has summarised recent events as “scope creeping”. 

[Dick Cheeseburger]

Great to see you continuing to exterminate the ginger bugs from the underside of the Fourtrak. 

It's brought back memories from just over a decade ago when my brother was into off-roading and greenlaning. I went out with him in his (now virtually extinct on these shores) J Top Pajero which performed amazingly all day. This poor old Fourtrak was being driven by a slightly overzealous lad who hadn't quite got the hang of things though... Paj to the rescue! 

I'd say yours has outlived the huge majority of it's brethren and then some. Keep up the good work!

[rickvw72]

 Thread resuscitation:

Spent ages back end of winter / early spring rebuilding my VW T25 engine, which went through my project funds like an oil rig fire.

so the old Daihatsu took a bit of a back seat for a while, but I did continue the grind of cleaning up the whole underside of the shitbox.

Clean machine 

Detailing World territory 

“Been in cleaner swamps”

Drove myself insane and deaf with one of these

Then had an issue with my trigger finger, so was on the go slow (looks like carpal tunnel) for a while.

Did a bit at a time, rust killer as we go 

I love you, Bilt Hamber Hydrate 80

After a very not short while, it was ready for some primer

Under the boot floor

Nearside rear arch and rear chassis

 Gearbox area, looking back

 

Inner arch and crossmembers, it’s the bit where all the suspension and rear axle go

in the bad old days

 inner arch was like this a while ago 

So, yeah I’m still going with the old knacker

and yeah, it needed so much welding it gave me carpal tunnel

Gotta love a Fourtrak