Hi Guys & Gals
I am getting ready to do a tear down / rebuild of my 94 YJ 2.5l auto. My plan is to begin the process May 1st as I am waiting for the salt&sand get washed off the roads here so I can take my new car out of winter storage to be used as a DD. I bought the Jeep last year for cheap ($1500) for the sole purpose of a winter DD and to replace my 4x4 Tacoma that Toyota had bought back. It will most likely be cheaper to repair then to try and find another Jeep.. The main reason for this is to repair some rust damage to the frame. In order to pass inspection last fall i shoved some fiberglass "kitty hair" into the bad spots on the frame, smoothed it out with a grinder and applied a very heavy coat of undercoating the day before the MVI so it was still dripping wet for the mechanic that had to look underneath it (worked like a charm
) The plan is to remove everything from the frame, cut out damaged sections / fab & weld in new metal. The old 2.5 liter engine runs like a top, compression is good, so other then a good cleaning no need for any repairs there. I hate the auto tranny but since my wife has trouble with a 5spd I will be sticking with it
Overall the frame seems fairly solid, but I realize that once I begin sandblasting the frame I may find its worse then I had thought!
In another thread here at JF it was suggested to use 3/16 steel for frame repair, does everyone agree??
Here's My YJ
Rust damage to driverside front axle leaf spring mount, notice the crack, there was actually a hole on the bottom of the rail inside the shackle but as i mention i filled it with fiberglass to get through an MVI
the rear crossmember that supports the gas tank is broken on both sides, tank is being held up by a tie down strap
the usual problem area isnt as bad as i have seen here at JF, although there is some rust along the botom of the rail here, hopefully i will be able to leave most of the metal intact here, notice the strap holding up the gas tank
Any tips are certainly welcome and I will update this build thread once i begin with pics at every stage. ( and most likely be begging for help