Hi everyone 

My name is Hannes, I'm 16 years old and living in Sweden.

Of course I have to start with an apologize for my bad english.

I started a build on a suzuki SJ413 in spring 2009 when I was 14. It's a low budget project. Trying to combine time for studies, lack of money and time for my girlfriend with this project. 


This was my SJ413 from the start - in really bad condition. I think it wasn't one part of the sheet metal in the body that didn't have any rust. To be honnest it was surprising that the body just didn't collapse. I was held together with plastic filler and paint.


But it was very very cheap so it was suitable for my means. The goal was and still is to build as cheap as possible. I have to buy second hand and manufacture as much as possible myself. It's a terrible scarcity of money but my time is for free. I can sleep when I get old 

Kind regards from

Hannes

Looks like a fun start to me.  You don't have to worry about wrecking the body if it is already rusted out. 

Have you done anything to it since last year?

I decided to start the body makeover in the front right corner.


The previous owner had repair all rust with parts of textile sacks and polyester filler. Perhaps he never have heard of the possibility to join pieces of metal together by welding.


So when I used a bodywork hammer and pounded on the fender everything just fell of.

So I carefully screw the fender away and found more proffesional repairs behind it that fell of just as easy as on the fender.


So here was where I started.

So here i have started the repair by welding some sheet metal.


Here the rust hole is history. After welding and grinding I did put on a thin layer of zinc and after that two component epoxi primer.

And this is me in the middle of that work 

Fenders for Suzuki Sj's are far to expensive for me. So I had to build it myself from what I got.


So first thing was to make the front corner and to rebuild the inner fender. I'm allways trying to be as near to the original that my ability and knowledge allows. This was a little tricky.


I'm lucky because my father has a SJ410 in perfect condition. That means that I allways can look at his Suzuki how things shall look like. I'm allways doing templates in paper for the sheet metal. Often I'm doing the templates from his SJ410.

So here I have started with the inner fender.


This is a picture of the sheet metal I've made for the sides of the fenders, You can also see the template made from my fathers SJ410. I also made the profile that should be along it and above the fender flare. That is done in a machine and in swedish that is a "sick". I don't know the word in english for it.

So here the inner fender is done with some zink on it.


After that the sheet metal on the side was welded into place. Also some small pieces under the front corner are in place.

I also have to do repairs in front of the door behind the fender. Here it is with epoxy primer on. I hate this color of the primer so later on I did buy some gray instead


Here the fender is rebuilt with zink on it...


and here with epoxi primer and fender flare. Before that I used tin/lead as filler and of course a lot of grinding and sanding.

"Before and after" pictures are funny

That is all for today 

Kind regards from

Hannes

Looks good. Thanks for sharing. Also, your English is actually very good.

-Eric

Thank you Drone637 and ebewley for your pleasant comments

Time for bed. The time is about 32 minutes after midnight in sweden 

/Hannes

Very, very good work! You have a skill that no one can take away from you. I will be watching the rest of this build....

David

Thanx for the positiv feedback Hillbillydave


I took the opportunity to fix the brakes on the right side now that the wing easily could be removed to make the caliper easy to access.

Yoke and the cylinder had been jammed together.