nor_al_67

About to start fixing the rust in my 1980 4x4. Drivers side is toast, I'll patch the passenger side. Won't look pretty, but hopefully it'll be strong.

nor_al_67

I've cut out sections of the ps floor pan. The rest is solid and will give a good foundation for the patches.




The seat mounting point end was pretty rusted, so I cut out that piece. Will rebuild it and then weld back on.





Here, I've cut out almost all of the ds pan.

nor_al_67

I couldn't find any first gen floor pans, so I took a chance and purchased a pan from an early Bronco. I got this off ebay ($60 shipped) and after trimming for the ds, I should have enough left over for the ps patches.

nor_al_67

I used a poster-board to make a rough pattern for the new pan.



After a lot of cutting and tweaking here's the ds pan. Note the exhaust heat shield. It is attached with 4 bolts that weld to the bottom of the pan; underneath the gas pedal.






Here's a shot of it roughed in, like I said it won't be pretty. I'm going to do a lap joint with plug welds. It is basically sitting about 2 cm on top of where I cut out. I'll paint, and seam seal the hell out of the connection areas. I had to cut 2 reliefs to get the pan to fit, will patch them later.

cascades

Nice work! Good to know a bronco pan can be modified to work. Have to remember that when I get around to doing my pans.

nor_al_67

Thanks, I will note that I'm using a Bronco passenger side pan for the Toyota drivers side. It's turned around so the slope side matches the tunnel. The reverse would be true too, i.e. use a ds Bronco pan on Toy ps turned around.

nor_al_67

I've finished welding and grinding, sprayed a coat of self-etching primer, top coat and started the seam sealer.




I rebuilt the seat platform.

nor_al_67

I did the gas pedal conversion thing that others on this site performed. I used a 2000 Toyota Solara gas pedal. I fabricated my own bracket that bolts to the floor with 1/8" metal. Cut the pivot shaft and switched sides. I took about 2" off the end of the Solara pedal that holds the cable and reverses sides of the end. Lastly I used a propane torch and bent the bottom towards the floor. I used the Solara spring and welded a little nipple for it to hook on the pedal. This is a nice conversion and makes the pedal work smoothly.

slacker

iTrader: (1)

looks good

nor_al_67

Finished with the pans. Will now apply some fatmat type insulation and a new floor covering.

nor_al_67

This is the new "beige" vinyl flooring from auto custom carpets.



It's a good match with my original.

nor_al_67

Got the seat re-covered. The local upholstery guy did a great job finding something close to the original tweed. Vinyl flooring semi-installed still need to trim a little more.

nor_al_67

Need to make a couple kick panels, still trying to decide whether to use cardboard, plastic or wood.

nor_al_67

Still looks pretty good in her original paint and >350k miles.

cascades

Dude! That looks great. Good looking rig!

faber

Excellent work! Great pics.

Lons81

iTrader: (2)

HAVOC

Nice work!
We really need a company to produce steel replacement panels for the 1st/2nd gen pickups.

nor_al_67

Thanks guys. And thanks to the website owner/mod for the front page feature. Agree that steel replacement panels are badly needed and interior parts too. Fortunately it seems most of the drive train parts are available.

HAVOC

It's why I've given up on driving a 1983 pickup. I bought two pickups, one a 1982 and the other was a 1983. The rust was so bad (I live in the North East), I had to scrap both trucks. The frames and bodies were too far gone.
My only option is to find one from the South West. I just bought a 2012 standard cab Tacoma 4X4 so the 1983 will have to wait