ckhorne's 1967 project

Builds, refurbishments, restorations, upgrades

Postby miller » Sun Apr 26, 2015 7:37 am

Looking great mate, well done!
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1964 MWB Soft top Patrol - 1972 MWB Soft top Patrol "Diablo" - 1977 MWB V8 "Mr Muck" - 1978 G60 Patrol Ute "HP"
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Postby Metaxas » Sat Jun 20, 2015 5:52 pm

Nice work!!!!
Hope you can post your finished work
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Postby RiverPatrol » Sun Nov 22, 2015 10:05 am

I moved the brake booster posts to a separate thread. Here is the link: http://www.60patrol.com/forum/viewtopic.php?f=4&t=3928&start=15
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Postby ckhorne » Mon Dec 03, 2018 9:03 am

It's hard to believe my last update on my own thread was 3 years ago.... hopefully I can bring it current again.

After a long hiatus of sitting in my driveway, with the occasional driving, I finally started working on the body. The PO went over the Patrol with rattle cans at some point, which was flaking off in most places and there were a number of rusted out holes. Overall, the body was in decent shape, with the majority of the rust limited to the corners and low points where water collects - no major dents or other problems.

I've always thought it'd be interesting to paint my own vehicle, and I figured I couldn't make matters much worse by learning on my Patrol. I also didn't expect Pebble Beach Concours - level finish - enough to look good from a few steps back was good enough. I knew nothing of automotive painting, including any and all prep work, so I really had no idea what I was getting into.

I started with a basic DA sander and 80 grit sandpaper (my son lasted about 10 mins before getting bored...):

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Somewhere in there, I realized that I needed to take all the panels off to really get to a lot of the rust. I finished the tub after going through about fifty 80 grit pads:

IMG_1319.jpg
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Postby ckhorne » Mon Dec 03, 2018 9:11 am

Next step was to get the first coat of paint on to seal the metal back up. I ended up going with Southern Polyurethanes for all my paints except for the color/base coat - mostly because of the online support and the excellent phone support.

I rolled the Patrol out into the garage one morning and, with my first attempt at using an HVLP gun, I nervously sprayed on two coats of epoxy primer. I look back later on myself and laugh, now knowing I had no reason to fear screwing up as much as I thought I did... Anyway, I made it through with only one paint run.

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Postby Esteban » Mon Dec 03, 2018 9:21 am

Excellent! :clap: :clap: :clap:

Certainly your updates have been missed! Your work with the paint will be interesting to follow, so please keep the pictures coming.

And talking about pictures, in the one showing part of the front-left without the fender, we can see a nice adaptation of a power booster. Please post some additional details and parts used.
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Postby ckhorne » Mon Dec 03, 2018 9:28 am

I parked the frame/tub to the side and started working on the other panels/doors/hood, but finally wised up to trying to find something other than DA sanding for stripping paint to bare metal. I settled on strip disc's - more expensive but far, far faster in stripping paint. In retrospect, I should have just taken everything to the sandblasters.... oh well... lesson learned.

The tub, still connected to the frame, was easy to roll around and paint. The other panels needed to be painted on all sides, so I had to figure out a way to do it in my driveway... and so my ghetto paint stand was created.

IMG_1452.jpg


Note the much heavier pitting and spots of rust - especially on the tops of the front quarter panels, which had sagged over time, and presumably water pooled up there. So... I fixed this by welding in a piece of channel steel under both sides after they were painted:

IMG_1465.jpg
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Postby ckhorne » Mon Dec 03, 2018 9:47 am

Esteban wrote:And talking about pictures, in the one showing part of the front-left without the fender, we can see a nice adaptation of a power booster. Please post some additional details and parts used.


Oh - I was the original poster in the Brake Booster thread - it was just moved out into its own thread for better visibility!

So after all the panels had a coat of epoxy primer on them (Southern Polyurethanes is very specific that the paint goes on bare metal, and then filler), I started body work. Now.... I realize that a purist will use a dolly and hammer and spend days/weeks/months smoothing out the metal until it's perfect. However, I'm a realist, and I was ok with bondo repairs, and so just limited myself to 1/16" of bondo or less. I ended up using Rage Extreme - about 2 gallons of it, and I probably sanded off 1.9g of that...

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What I didn't realize until later (until after all the filler was done) was that there's a reason I was recommended the high build primer when I bought my paint... I sanded the bondo until it was almost glass smooth, not realizing that the primer is designed for the last few microns of smoothing things out. Good news is that I saved myself about 3/4gallon of primer. Bad news is that I spent months doing fine block sanding that I didn't need to.... another lesson learned...

Anyway, after all the filler was done, I sprayed on another coat of epoxy primer to seal the exposed metal, and then a couple coats of primer:

IMG_2491.jpg


IMG_2490.jpg
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Postby ckhorne » Mon Dec 03, 2018 10:03 am

At this point, I realize that my "good enough" paint job has become more exacting than originally I set out for it, and that I was more impressed with my first paint job than I had expected of myself. Not perfect, but better than my low expectations.

Anyway, at some point I had to figure out what I was going to do with my hard top and rear doors. The hard top was in terrible shape - it was rusty, had holes, and was more bondo than metal in many places. And the rear doors were almost beyond repair - the bottom of both doors were completely rusted out from water collecting there, and one had tons of bondo filling the holes from the PO:

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So... I explored options, and found that rrodriguezsal here on the boards offered a soft top frame, soft top production, and rear doors, all for a very reasonable price shipped from Bogota. I always liked the idea of a soft top anyway, so I ordered everything. It was a pleasure working with Raul, and I'd recommend his work to anyone on here.
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Postby ckhorne » Mon Dec 03, 2018 10:09 am

I assembled and test fit the rear canopy on mid-progress:

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And the canopy at one point:

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Excellent fit and finish. Rear doors were a perfect replacement too (just set in place... no hinges here):

IMG_2212.jpg
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Postby ckhorne » Mon Dec 03, 2018 10:13 am

After everything was primed and sanded to 220 grit, I sealed it with reduced black epoxy one last time.

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I went round and round about how to best paint the hinges and bolts. I'd get the best results if I painted them in place, on the body, but I'd break the paint if I ever had to remove anything. In the end, I painted everything separate. This later meant that all the screws that needed to be body color would also be painted separately.... what a pain...
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Postby ckhorne » Mon Dec 03, 2018 10:26 am

For the sake of anyone reading this in the future, I want to talk tools for a minute. This whole project was sponsored by Harbor Freight it seems. Not because I wanted to cheap out necessarily, but because I couldn't justify buying $400 HVLP guns and the like for a one-off project. My HVLP guns, blast cabinet, straight line sander, and even air dryer are all Harbor Freight specials.

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Unlike my son and sanding, I couldn't pull my daughter away from the blast cabinet...

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My welder and other long term pieces of equipment are higher quality. Sandpaper is another place that I realized quickly that it wasn't worth buying the cheap stuff.

Painting your own vehicle is doable at home, with modest equipment. It's terribly time consuming and still requires a lot of random pieces of equipment, but doable. If you enjoy doing something yourself, go for it. If you're looking to save money, reconsider....
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Postby RiverPatrol » Mon Dec 03, 2018 10:28 am

Great progress! Thanks for the update.
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Postby ckhorne » Mon Dec 03, 2018 10:44 am

When I started stripping everything, I had intended on leaving the interior until after everything else was done, just to limit the project scope. But after a bit of painting, I realized that it'd be a lot easier overall to just bite the bullet and do the interior at the same time.

I had never intended to paint the inside of the rear tub. I just don't like painted metal interiors - they look nice... when never touched. The problem is that if you use your truck for any kind of utility, it's going to get scratched. I took my 3-day old Tundra (with < 15 miles on it) to get the bed Line-X'd, with zero regrets. So... the inside of my Patrol will be Line-x'd. If I'm kicked off the forums after saying that, you guys know why... ;)

However, I did want my dash and front door interiors to match the body color, so I started stripping things down one night:

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A lot of stripping, spot sanding, and more practice on welding patches in body panels later:

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Painting with a HVLP gun inside those foot wells was tricky, at best. Hard to keep a consistent distance and speed inside a cramped space, but everything came out surprisingly good.
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Postby ckhorne » Mon Dec 03, 2018 10:57 am

And then comes up to my first big mistake. I had waffled on the paint color for a while, and I had pretty much settled on a blue - likely a darker blue from the period. But when I got my canvas in, it just had too much of a hint of green to get away from anything other than white, black, tan, or green. The first two were out, and between the last two, I went with a green.

I wanted to avoid PPG just because of the cost, so I called up Southern Polyurethanes for a reference. They sent me to a shop they work with who could mix up Motobase base paint. Cost was around $400 for a gallon of base and a gallon of reducer.

The day came to paint my base coat + clear coat. I was a slave to the weather and timing, so I had to pick a day that would hit around 80 degrees and 50-70% humidity. I setup a ghetto paint booth with a couple of 10x10 canopies, a bunch of plastic, and a box fan and HVAC filters:

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Hey - don't laugh. It worked. :)

I moved the panels all inside and painted:

IMG_2605.jpg
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