[D0ntTr3ad0nM3]

Alright so I'm not entirely done with this project. But I'll keep ya up date.
Basically I started this like everyone else after I pulled up the drivers carpeting, the passenger is fine.

There were several obstacles I had to deal with along the way.
1. I didnt know how to weld
2. I didnt have time to learn right now
3. I didnt know anyone who knows how to weld.

So i decided on using Fiberglass, which according to several sources is pound for pound 5x stronger than steel. Heres the process:

Step 1:
Look at all the ungodly rust, I still don't know how I didnt fall through.
http://i209.photobucket.com/albums/bb235/D0ntTr3ad0nM3/DSCN0528.jpg
http://i209.photobucket.com/albums/bb235/D0ntTr3ad0nM3/DSCN0529.jpg

Step 2:
Start cutting out the rusted metal using a dremel and cut off wheels (the following pic is after 20, I used 7 more to get it to the second.)
http://i209.photobucket.com/albums/bb235/D0ntTr3ad0nM3/DSCN0531.jpg
http://i209.photobucket.com/albums/bb235/D0ntTr3ad0nM3/DSCN0532.jpg

Step 3:
Admire your work, read paper on the garage floor.
http://i209.photobucket.com/albums/bb235/D0ntTr3ad0nM3/DSCN0533.jpg
http://i209.photobucket.com/albums/bb235/D0ntTr3ad0nM3/DSCN0534.jpg

Step 4:
Make a template out of a paper bag.
http://i209.photobucket.com/albums/bb235/D0ntTr3ad0nM3/DSCN0535.jpg

Step 5:
Lay template onto green flower foam to make a mold.
http://i209.photobucket.com/albums/bb235/D0ntTr3ad0nM3/DSCN0537.jpg

Step 6: Cut and sand the mold to make a proper shape. Cover with Wax Paper prior to fiberglassing.

Step 7: Follow Directions on Fiberglassing kit, and lay in first layer
http://i209.photobucket.com/albums/bb235/D0ntTr3ad0nM3/DSCN0538.jpg
http://i209.photobucket.com/albums/bb235/D0ntTr3ad0nM3/DSCN0539.jpg

Step 8: Remove Foam Mold

Step 9: Sand down any inperfections using 60 then 100 grit sandpaper.

Step 10: Seal the underside using a silicon gel
http://i209.photobucket.com/albums/bb235/D0ntTr3ad0nM3/DSCN0542.jpg

Step 11: Add a couple more layers of Fiberglass for strength. Add metal mesh for structural integrity.
http://i209.photobucket.com/albums/bb235/D0ntTr3ad0nM3/DSCN0543.jpg

(Yet to be done)
Step 12: Cut fiberglass edges and cover entire area w/ body filler.
Step 13: Herculine and done.

[Joe Dillard]

Step 14: Drink beer.

Looks like it'll be nice when all is said & done.

[D0ntTr3ad0nM3]

Yea, for the 21+ group, I forgot to mention the 2-24 packs of Pepsi that was consumed.

Update:
Got most of the body filler on, it was so much easier than the guessing I had to do for the Resin. Just have to do the edges and sand after work today. Then i can get started on the herculining.

By the way, if anyone is reading this and saying to themself "Well I have no experience with Fiberglass I can't do this", I'd like to mention that this is my first time working w/ fiberglass or Bondo, and if you can do Bondo, you can do Fiberglass with some patience, and lots of rubber gloves.

[brianwi11iams]

Nice writeup! My floor isn't quite that bad, but I'll have to tackle it sometime this summer. I never even would have thought of using fiberglass.

[pasinbuy]

Fiberglass ? New idea I am curious if it will work and not crack. Looks good. I just did my floor on my 94. It was funny to me that the driver side was rusted out but not the passenger side on mine, yours too?

[Jeeples]

Originally Posted by D0ntTr3ad0nM3

Alright so I'm not entirely done with this project. But I'll keep ya up date.
Basically I started this like everyone else after I pulled up the drivers carpeting, the passenger is fine.

There were several obstacles I had to deal with along the way.
1. I didnt know how to weld
2. I didnt have time to learn right now
3. I didnt know anyone who knows how to weld.

So i decided on using Fiberglass, which according to several sources is pound for pound 5x stronger than steel. Heres the process:

Step 1:
Look at all the ungodly rust, I still don't know how I didnt fall through.



Step 2:
Start cutting out the rusted metal using a dremel and cut off wheels (the following pic is after 20, I used 7 more to get it to the second.)



Step 3:
Admire your work, read paper on the garage floor.



Step 4:
Make a template out of a paper bag.


Step 5:
Lay template onto green flower foam to make a mold.


Step 6: Cut and sand the mold to make a proper shape. Cover with Wax Paper prior to fiberglassing.

Click Free

[Jeeples]

Step 7: Follow Directions on Fiberglassing kit, and lay in first layer



Step 8: Remove Foam Mold

Step 9: Sand down any inperfections using 60 then 100 grit sandpaper.

Step 10: Seal the underside using a silicon gel


Step 11: Add a couple more layers of Fiberglass for strength. Add metal mesh for structural integrity.


(Yet to be done)
Step 12: Cut fiberglass edges and cover entire area w/ body filler.
Step 13: Herculine and done.

.....And the rest

[Jeeples]

Originally Posted by pasinbuy

Fiberglass ? New idea I am curious if it will work and not crack. Looks good. I just did my floor on my 94. It was funny to me that the driver side was rusted out but not the passenger side on mine, yours too?

Nothing really new, several manufacturers have been making CJ tubs entirely out of fiberglass for years.

To the OP:

Make sure you dont put tons of bondo on there, it really should only be used to fill in the low spots in your 'glass. If possible, avoid going more than 1/8" thick covering of bondo over the entire surface. I would hate to hear how the rest of your floor pans rusted from the inside out because of trapped water seeping into any cracks.

[pasinbuy]

Jeeples, Thank you for the reply. I was refering to a repair over steel for a floor to fix rust in a spot that takes a beating this is new to me. Has that been done many times b4? Is this a good repair for me to keep in mind?

[ovrlnd]

looks like you did a nice job. fyi tho if you really wanted an easy fix for that you could buy a replacement floor board, trim and clean and just JB weld it to the tub. we did this on a friends trail jeep and has held up remarkably

[D0ntTr3ad0nM3]

Jeeples Thanks for the click free. Btw with the bondo, ive been doing it kind of thin, but im planning on putting herculine over the top, would I still have to worry about water? I agree having other stuff rust out is going to stink. I'm going to be tackling the "Jeep" logo rust spot on the outside, and a spot on the fender next.

Pasin- So far I've had myself (~170) and about 100 pounds of free weights, and havent so much as heard even a creaking noise out of the floor. I'll keep this updated if problems arise, so far so good.

Ovrlnd- I thought about that, but decided against it because this is my DD and wanted to get somethign I was confident in.

[Shinner]

Dang, I thought mine was bad! We just cut out the rot and welded in a new pan from Quadratec. Painted the underside with undercoating, hit the top side with some paint. Just need to find someone to weld the passenger side for me. If I could get that done this summer, I can start thinking about lining the tub.

[D0ntTr3ad0nM3]

So i got most of the bondo on today, just got a little bit more around the edges. The only complaint I have about this whole project so far is the AWFUL smell that goes with it.

I guess I never actually realized how bad the rust was until I took it all out, and looked at it in pictures, oh well at least its gone.