[Andygoodbloke]

Bad news

My SJ50 / 413 build was nearing the end and I took it in to be tested to ensure it was safe to return to the road.

The inspectors asked about the repairs around the back arches for the back wheels. (see my build story) They do not believe it is structurally sound,( I do ) so have asked me to get it certified with a structure focused panel beater.

After sending emails to a handful who are able to certify it as being safe one replied and advised

The repair has to be undone and redone by them the bill was estimated to be around $3150nz which is more than I paid for the vehicle.

I maybe able to lower the price and take it apart myself, but not that majorly

Has anyone got any suggestions on how to fix these holes, once stripped back down?
One of my thoughts is to take the wheel arch off and raise it to the point where it can be reconnected.
Another thought is to find a ruined vehicle and take a body section from it on both sides, if I can find one which isn't rusty.

Any ideas of which one would be easier or a better repair? May have to look into getting a Tig welder for the thin body metal and argon gas. But the approved repairer should do the work or they won't approve it.

Or throw it away?

Opinions please, particularly if you have had a similar issue
Not happy
Thanks Andy

[UBZ]

Read the NZ regulations around rust repair . Nothing says you can’t do it yourself . I’ve fixed and had woffed plenty of my POS junk over the years
The 413 has a ladder frame chassis , so the body is not considered “structural” . there can be no corrosion around pillars , corners , body mounts and seat belts etc . That would mean threat to the driver in an accident .
As long as the repairs are reasonable , ie not just bog and do no pose a threat to pedestrians ( ie sharp bits) there should be no reason to reject them
I would seek a 2nd option .
Photos of the repairs ? You defiantly would fail if the holes / sharp edges were left as above .

[UBZ]

Looking at the pics in your build thread ,
Pop Riveted sheet metal is defiantly not an approved method of rust repair. Especially over such a large area .

Those patches need to be welded in .

[Andygoodbloke]

Thank you for your replies UBZ
It is very useful information I had not considered with the ladder frame.

I can only assume the holes were cut for rust as I did not do it, but the metal around the holes is totally rust free so maybe they were planning to lift the wheel arch as a virtual lift.

I will talk to a structural panel beater and see what he says and how much it will set me back but I am considering removing our repair making patches and getting them to weld and approve if I have to, or actually do the virtual lift for the back wheels

Cheers Andy

[Andygoodbloke]

The latest o this ongoing saga which is taking up too much space in my mind.

I spoke to structural panel beaters / welders and put to the the fact the body can be taken off as a removable part, as the bonnet or doors come off but a few more bolts.

They emailed me pictures which cover all vehicles including Ladder chassis stuff showing what they consider "structural"

They advised to get it legal it will have to be taken back to OEM (Original Engineering Material) so would need a donor vehicle to cut up.

I found one and the body needed would cost me $400 nz and I would go further and take the whole wheel arch too the issue then being cutting up the project vehicle and welding it in as I haven't got the skill to weld this as it is a big area and connects to the B pillar behind the doors, I did think about a big cut to take the whole back quarter from the door shut to the back door both sides - my conclusion was too much work and too easy to make a mess of it

I am thinking now of a virtual lift and simply raise the wheel arches a little and have found some one willing to do this and I am awaiting a price, but he is an hour and a half away. The other option is to cut the folded edge back and weld along the join of the wheel arch and up where it is currently joined to the body.

I also advertised it for sale for what it has cost me and had lots of interest but on FB Market place people don't read the ad and kept asking stupid questions, but if some one is willing to pay for it they can go for it.

If any builders / welders / fabricators around the Christchurch area want a cash job, let me know as I want to get the thing road worthy but don't want to spend the kids inheritance to do it and taking it to a structure welder will cost around $3200nz which is why I considered selling it as an off road / hunting&fishing / farm vehicle.

Let me know if you are local and have the skills and a tig or mig and can do the job for me.

Thanks Andy

[Andygoodbloke]

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An update.
I went to sell the project, but could not go through with the sale and withdrew the sale, after all I have thrown a lot of time and effort into this project and I found it hard to let go - you can buy my kids cheap however (kidding)

I looked for some one to undertake the repair job and fill in the holes and make it better. After a while looking I found some one who could help, a fellow Suzuki enthusiast too.

He is a fabricator and no stranger to Suzuki Samurais / Sierras. I can speak very highly of the work of Callum Hunter of "Hunter Customs" if need body work done around Christchurch New Zealand - he is a good bloke.

He filled the holes in and now the job of tidying begins again.

[Gwagensteve]

Good to see it repaired well.