I've received a few inquires as to how I did my Herculiner install on my YJ. I figured I would through it up on here with some of the down and dirty basics.
I cannot stress enough that the amount of preparation you put into your work is going to directly affect the outcome. Put in the extra effort!
I recommend that you have a lot of small ziplock bags available. Use these to put bolts/parts in as you remove them. You should also label where it came from. For example, "rear bench bolts."
A single Herculiner kit (1 gallon Herculiner, 1 roller handle, 2 rollers, 1 scouring pad) is sufficient to complete the job but to do a great job I would recommend purchasing the following:
- 2-3 more scouring pads
- TSP Substitute (this is in a liquid form and is non-toxic so you don't need to worry about clean up and disposal as with regular TSP)
- Blue painters masking tape
- Paper "drop cloth"
- Torx bit set - Use a higher quality set (Craftsman, Snap-on, etc as poor quality torx bit will simply "twist")
- Security torx bit set
- Elbow grease
- Various screwdrivers
- Socket set
To start begin by removing all seats. This includes any risers they may be attached to. For a YJ there are 4 bolts each for the front 2 seats bolted to the tub. The rear seat is secured with 2 brackets to the bottom of the tub with 4 torx bolts. You also need to remove the brackets from the side of the tub that secure the rear bench down.
Next, remove all seat belt bolts. There are 4 bolts in the rear for the bench (YJ). For the drivers seat there is one bolt on each side mounted on the roll bar. This is a security torx bolt. There are 2 more torx on the tub, one on each side of the seat.
Remove the center console. On a YJ there are 2 bolts on the bottom of the stock center console. Next, remove all of the carpet and carpet padding. Remove all drain plugs and keep them in a safe place if you plan on reusing.
Remove the nobs on top of the shifter (manual trans) and T/C shifter. Unbolt the rubber jackets over the shifters. Remove the metal plate that shields the transmission.
Now remove any door latch assemblies bolted to the tub. This includes the tailgate.
On the tailgate, be sure to remove the latch assembly that is on the door as well as the plastic cover on the lower arm.
Start removing the roll cage. Unbolt the roll bars from the windshield. Next, begin to release the windshield to be able to lay it down (bolts at the bottom of the windshield on either side). Then go to the main hoop and slide the padding towards the windshield end. This will expose a security torx bit. Unbolt that bit and remove the bar that connects the main hoop to the windshield. After both sides have been done begin removing the torx bolts from the tub. Pull the roll cage out.
This is what you should see
Start cleaning out the tub. If you have any rust, hit it with a wire wheel. Clean the tub out with some water if its really dirty. Next, hit it with some TSP. This will get rid of any grease and stuck on grime.
Next, using the scouring pads, scrub the entire tub down with acetone. You are trying to remove all gloss. You also are trying to create a rougher surface for the Herucliner to bond to.
Now begin to mask off the areas you do not want to be covered. This is all bolt holes and drain holes. For the drain plugs I went a different route than most. I covered the entire drain hole with tape and then cut a circle out of it using a scalpel. It worked out incredibly well and created very sharp, clean looking lines.
For the bolt holes I used the small wads of tape. Be sure to leave a bit through the top that you can use to pull it out. For the smaller holes (the center console and the strap connectors next to the door panel on the floor board) I used match sticks. They worked great. Mask off all areas you do not want to be covered with masking tape. Here is a completed masking job on my YJ tub. I chose not to put Herculiner under my roll cage mounts. Either way would probably work fine.