Giving the Jimny a birthday

To loosen rusted bolts and nuts I can recommend an induction heater. This also might have helped you with your calipers. I use this one:
 
 

I was actually looking at these yesterday.  Much better option than forking out a grand or so for a gas axe set up. I'm replacing most bolts with stainless, so hoping 'next time' won't be so bad. I'll definitely chuck one of those in my basket in future and give it a try.

If you replace your bolts with stainless make sure to all grase them on the thread. Otherwise they seize up, almost for sure. And they usually have less strength so do not use them on structurally important places.

Maybe better are bolts that are properly galvanized.

The (in my opinion only) advantage of a gas burner is that it can also heat up the outside and sometimes this is much better than heating from the inside.

RainerK wrote: The (in my opinion only) advantage of a gas burner is that it can also heat up the outside and sometimes this is much better than heating from the inside.

Well, I think it will have to be an addition for the toolbox as I can always pop over to my mates who has the gas axe if I get stuck.

Also gas has the advantage of being able to braze.

Roger

Did a few jobs this weekend

• confirmed my AC gauge set was not leaking and identified a small leak on the AC system.  However, could be due to the system not being used for so long, it's not sealing correctly.  So I'll have to half charge it with dye and identify it.
• Drilled out ABS sensor bolts on front hubs and reclaimed the holes to be used again.
• Drilled out and retapped 2 bolts on the AC condenser mounting bracket
• kingpin bearings plus shaft seals renewed and hubs refitted to front axle
• wiped down plastics inside car as they were very dusty
• shampooed head liner inside car to remove unwanted 'welding scent'
• fabricated two more brackets for the ABS cable on the rear trailing arms
• fitted ABS sensor cable to front axle with p-clips
• partially fitted hub vacuum hose as I ran out of clips

Today, as the weather is terrible and snowing, I've been inside designing and 3D printing some brackets for the hub vacuum hose and also clips to replace the old fuel line and brake line holders running along the chassis.  Not going to win any design awards, but at least I've done something semi productive today.

Thanks Lambert,

It's just taking forever to do the last jobs.  Still waiting for the new arches, so can't do anyhting until I can see how the bumpers line up. In case I need to redrill them.  This bout of snow the past few days has put a stop to work tho.

Fantastic to see so much love go into your jimny diy style
Hat's off to you great work 

Thanks Jack,

It's never going to be perfect, but it's nice to save a small fortune by applying some knowledge and getting a similar result to what I want.  I've also enjoyed learning some new skills and techniques along the way.  However, there's still a long ways to go yet as I've got to modify the front and rear bumpers to match the new arches, a lot of faffing around with filler paste and sandpaper unfortunately.

Jobs done over the weekend

• secured the hub vac silicone hoses using my 3d printed brackets design
• secured brake and fuel lines using my 3d printed brackets design
• serviced brake calipers, painted them orange and fitted them to the jimny
• fitted steering rod and tracking rod
• realligned steering to centre steering wheel
• fitted steel wheels
• fabricated washers for interior components fitment to new boot floor

Jobs done today

• fitted rear light clusters back on
• fitted plastic interior trim for rear
• fitted rear seats (seats aren't going in, but the plastic liner I have for the back sits on them)
• ran in and tie wrapped breather pipes for axles, g/box and t/box (still need to fit the manifold somewhere in the engine bay)
• painted slam panel with a coat of primer

Jobs for the rest of the week:
too many to mention because I keep adding them on all the time    I'll get some pics of what I've done as I usually leave the phone in the house to prevent distraction when working.