FJ40 Sill Replacement

Sill repair:

The rear sill structure on an FJ40 is usually another area that hides corrosion. My 78 had a toasted sill with old PO fiberglass repairs and a nice layer of bondo over that and the rust. The sill horns mate flush to the inside fender/quarter panel which is another big moisture trap. These guys get pelted with wet road stuff and whatever else is thrown up by the tires.

There are several after market sills ...

The floor is usually in bad shape around the sill ...

Inside SeamPassenger side seam

My 78’s driver-side sill area, showing PO's repair attempt at some point in the past.


completed reworked sill

My newly completed sill, reworked from older parts with newly fabricated channels ...


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