87 Suzuki Samurai

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Quality custom & restoration sheet metal work & repair

To be air pump box installed.

I worked as many of the dents out as possible when bracing wasn't in the way then used Iceing glaze coat for skim filler.

After some thumping and bumping with a minor sand out the dents were removed clean no filler will be needed here.

Now its clear coated on the inside.

Removing the tub dents.

The owner brought in this 2 sided panel and wanted it used for an air compressor mount. So a little trimming and weld in 3 retention nuts so its removable if needed later.

Start primer blocking.

All the parts that needed base color coat are painted first round.

The left driver drain plug area is rusted so it will need replacement. The replacements is trimmed but not to small to remove the rust out area.

There is some ugly previous repair work around the wipers so he wanted that fixed also.

After grinding the welds I used my high tec pin hole checker.

Also the owner wanted to dents in the hood removed.

The Passenger side floor patch and the inner firewall side also painted I use Zero rust as it is sand able and paintable, I also sprayed undercoat on the underside of the floor patches for protection.

Final trim on part and cutout before welding.

Now for the right side with a little more work.

First from underneath I worked the torn area back to flat then ground it for a good weld.

The owner brought a bunch of replacement parts. Front fender upper and lower grill facias,and floor repair sections.

The owner wanted the rear tubs dents removed

I media blasted it to see how bad it is not bad still useable.

Patch painted with rust preventative paint.

The right seat rear mount area was torn and caved in.

I will start blocking primer in 2 days I like it to be well cured for first blocking.

Optional rust might cover up material installed at some point.

Patch area cut out.

Underside shot with Raptor bead liner.

Minor dents in the rear fender tubs.

First the patch will need a patch.

Owner supplied used patch panel to replace the rusted out area.

All sanded, cleaned, masked up and ready for first round of epoxy primer.

I cut some 14 gage stock and bent up some mount brackets , welded some nuts on the bottm for removability then welded the mount brackets to the 3 sides.

welding it slowly so no shrinkage distortion.

The patch for the patch trimmed to fit.

87 Sazuki Samurai

Missolanious rust repair.

Rusted out firewall section removed.

Rusted floor area cut out.

The new used patch also had some rust issues and was covered up with filler.

Everything blocked out real well.

Exterior parts fitting together.

The patch welded and ground clean.

Fully welded then ground clean.

I started long boarding the hood out there was enought material on it to get a good start to straighten it out.

Primed first round.

I removed the windshield panel as I did not know what was behind the problem area and I felt I could do it easier and a little faster and a cleaner repair.

The rust mites were a little active but some slow tack welds took care of the issue.

Final trim to fit its held in with magnets here.

Its all sealed up now no pin holes with the checker.

The battery sat next to the firewall so the acid rust mites were active inside shot here.

Started grinding weld down slowly as lots of irregular surfaces, plus will have to do some more welding to finish both sides to get real clean look.

Lots of tack welds to keep distortan down.

Ground clean, one more on the owners to do list.

Base coat color.

Yes the acid rust mights were active over the last few years.

The inner side bolt area for the passenger seat had some rust and cracking so I cleaned up the rust welded the cracks than ground the welds down.

Every bolt and screw were stuck so I had to use the hot wrench to get them loose.

Patch welded in and ground clean.

Found a spot on the lower belt line need a fix.

Re assembly of cut in parts.

Door hinge areas had light rust sanded it clean and painted also.

Also the rear tubs after dent repair the owner is planning on putting down bed texture in the back and front floors.

After snaking the new windshield washer fluid line thru the dash, a pain to do and installing the new windshield frame mount seal I reinstalled the windshield assembly.

I put some clear on it then remounted the front bumper, headlight assembly and sort of reinstalled the grill different mount points on the aftermarket parts. That the owner supplied. The owner has other work he wants to do later.

Thats it for this project.