[northjeep]

RUST!
EDIT Mar.29.08: This thread isn't really a "how to" fix a frame. I'm not really going to narrate the process. I'd rather let the pictures speak for themselves if I can.




It's not really a surprise.



The frame cracked while I was on my first 4x4 rescue mission.

[Joe Dillard]

That's ugly, but you already knew that.

Yeah, I'm sure there's at least a little back there, but not much. My YJ has been garaged in SoCal almost all it's life & I do very little mud/water and it hasn't been a daily driver for ~8-9 years.

When I first bought my YJ, I drilled a small hole below where the rear frame bushings are to help drain any water. It seems to have helped.

[pat8942]

20 years in the great white north has it's effects.
I have a 92 that lived in Michigan for 12 years but it had very little rust but since I moved to New Mexico it went into remission.

Originally Posted by Joe Dillard

That's ugly, but you already knew that.

Yeah, I'm sure there's at least a little back there, but not much. My YJ has been garaged in SoCal almost all it's life & I do very little mud/water and it hasn't been a daily driver for ~8-9 years.

When I first bought my YJ, I drilled a small hole below where the rear frame bushings are to help drain any water. It seems to have helped.

[BlackRhino]

I have a little bit of rust on the underside of the frame below the shackles. It's only a tiny bit though, no where near compromising. That, along with three other small rust spots on the body are as much as I have. I got lucky, since I didn't check as thoroughly as I should have when I bought it.

[Alacran]

No rust at all. 94 with 89k. Bought it in L.A. And is that snow in your shop?
Dang, no wonder you have rust!

[northjeep]

Originally Posted by Alacran

No rust at all. 94 with 89k. Bought it in L.A. And is that snow in your shop?
Dang, no wonder you have rust!

That's not snow it's baking soda all over the place cuz I stink real bad from working on the frame.

[bigh20rnr]

No rust on my 87 but it spent its life in Mississippi and the PO had it undercoated pretty regularly.

Rick

[rustywrangler]

Yep, mine has a soft spot in that area. I am not looking forward to getting into that. Yours is 10X worse than mine though. What are your plans??? bring it back to stock or just fire away with some 2x4 tubing and make a custom, STRONGER, rear frame area???

[northjeep]

Originally Posted by rustywrangler

Yep, mine has a soft spot in that area. I am not looking forward to getting into that. Yours is 10X worse than mine though. What are your plans??? bring it back to stock or just fire away with some 2x4 tubing and make a custom, STRONGER, rear frame area???

This thread will be updated as I work.

My plans are to rebuild STRONGER.
But 2x4 wont work to my liking (my frame is 2-1/2" wide)...and there's no such thing as 2-1/2"x4 that I can find....soooo I'll be fabing up a pair of rear frame rail stubs to graft on with plenty of fish plating. I'll also be upgrading to a 2x2 rear crossmember , and bolting on my bumper this time instead of welding like I did when I was in denial about the rust.(EDIT: 2x2 member and bolting the bumper went bye bye in favor of simply welding on my 4x4 bumper to the frame [inspired by the thread in the next post]...keep scrolling you'll see)

While I'm at it, my gas gauge is messed (reads 1/2 at Full and Full at Empty!!!)...so Im'a replace the sending unit and gauge with a cheapy I got at princess auto...(harbor freight).

[rustywrangler]

Originally Posted by northjeep

This thread will be updated as I work.

My plans are to rebuild STRONGER.
But 2x4 wont work to my liking (my frame is 2-1/2" wide)...and there's no such thing as 2-1/2"x4 that I can find....soooo I'll be fabing up a pair of rear frame rail stubs to graft on with plenty of fish plating. I'll also be upgrading to a 2x2 rear crossmember, and bolting on my bumper this time instead of welding like I did when I was in denial about the rust.

While I'm at it, my gas gauge is messed (reads 1/2 at Full and Full at Empty!!!)...so Im'a replace the sending unit and gauge with a cheapy I got at princess auto...(harbor freight).

In that case, here is a thread I was following for reference on a custom rear crossmember to do just that. http://www.jeepforum.com/forum/f12/custom-rear-frame-cross-member-442274/

[northjeep]

Originally Posted by rustywrangler

In that case, here is a thread I was following for reference on a custom rear crossmember to do just that. http://www.jeepforum.com/forum/showthread.php?t=442274

Thanks for that...
I like how the frame ties into the bumper with some triangulation on that build....But what's the argument for and against welding the bumper on again? I forget the pro's and con's of the weld on vs. bolt on bumper.

[rustywrangler]

Originally Posted by northjeep

Thanks for that...
I like how the frame ties into the bumper with some triangulation on that build....But what's the argument for and against welding the bumper on again? I forget the pro's and con's of the weld on vs. bolt on bumper.

As long as your bolting it on with good hardware, your should not need to weld it on. Just for the simple conveinience of being able to take it off if you needed to.

The big part about bolting the bumper on is when your using the "stock" stamped crossmember. It really cannot handle too much with a larger bumper.

[northjeep]

You can plainly see some issues here...

The previous owner made crappy repairs with 1/4" flat stock and tack welds



You can clearly see the crappy flat stock repair here...

I'm going to put a 3x3 in for strength, and weld...shimming if necessary for the body mounts.

[WCoon]

Yup, at least your tub is okay. On mine that whole rear corner is trashed. The body mount and the piece of the crossmember that it bolted to fell out one day on the road. I just started my build/repair. Pics are in my thread (just a couple below yours).

[northjeep]

Here are some more pictures of the repair process.



The new frame piece


A failed attempt at fabbing up the frame piece...there were internal stresses that made this piece warp all to heck.