Suzuki Samurai SJ413 JA51 Fender Repair & Bodywork 5 of ?

The Right-Way to Remove Loosen Rusty Bolts.

The Right-Way to Remove Loosen Rusty Bolts. The worst thing about working on old car, trucks or jeeps is loosening/removing the rusty frozen bolts and rusty nuts. As long as there are no rubber parts or anything flammable nearby the best thing to use use to remove frozen rusty bolts or nut is heat from a propane torch. You can use an acetylene torch also but you have the danger of overheating the metal and melting it. The heat from the propane torch is just right to free the rusty bolts up. Heat will work to free up frozen bolts much better than any penetrating oil. Btw, (if you have the time) Kroil is about the best stuff there is for penetrating the threads on rusty bolts. Another trick with using heat from a propane torch is that is the perfect amount of heat to remove bolts or nuts installed with Loctite Red. Loctite Red is typically used for a permanent installation. You need heat to break down the Loctite Red if you want to remove the nut or bolt. The heat from a propane is perfect for that. A heat gun may not be hot enough and an acetylene torch could melt things too much. The other trick for the worst stuck fasteners - nuts and bolts is to use reverse drill bits and easy-outs. If you use heat and then try the easy-out, you will often have no problem when using them combined. Again use the propane because you will not melt the steel. Sometimes just drilling with the reverse drill will un-thread the broken off bolt that is stuck inside. Also sometimes drilling off the head of a bolt will relieve a of of the grip and that helps when using the easy-out.

Suzuki Samurai SJ413 JA51 - Fender Repair & Bodywork 2 of ?

Suzuki Samurai SJ413 JA51 - Fender Repair & Bodywork 1 of ?

The fender on this Suzuki is not the same as a Samurai fender. It's actually a Japanese model Jimny JA51. I think a SJ413 or SJ410 may work but would have to be shipped from western Canada to Florida, USA so I decided to fix this one. Plus most of the time aftermarket fenders might not fit right anyway. Most of the sheet-metal on the Suzuki Samurai, SJ413, SJ410, Jimny JA51 is about 18 gauge and very easy to cut, bend and work with. You definitely don't need a plasma cutter or anything special to make a fast clean cut in 18 gauge sheet-metal and a jigsaw works extremely well. After this patch panel is fine-tuned, I will weld up where I had to make a couple cuts, then I will cut out the damaged area on the fender, flange all the way around with the flange tool and then use panel adhesive to glue on the new repair panel I made.