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Unread 02-29-2008, 08:20 AM   #1
LilViper95
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My Rusty Wrangler Project....

I recently purchased a 1990 Wrangler 4.2L 5spd from a friend. It only has 114k miles and has been sitting since 2002. He knew it was in need of some serious rust repair and it did not run when i bought it, sooo I didnt have to pay too much. Had a friend haul it home, changed the oil, fuel pump, put some plugs in and she runs great! (still gotta drain the tank, its running off a gas can attatched to the bumper)

Here are some pictures after I got it home and started poking at the rust.


The wife and her dads 68 440 powered Valiant in the background!


most of the rust you see is just surface rust on this side.


Gotta get rid of the chrome bumper, thinkin bout building my own!


Extra water drainage!! This area is really worse than it looks


This hole opened up a lot when i removed the bars.

Now I know there are lots who will tell me this is junk and good for no more than a parts jeep...I have been building jeeps for 13 years (i have dealt with this type of rust before) and my father in law is a body man and has fixed far worse, he restores old mopars. I did try to find a tub in the local salvage yards but there are none around, the good news is I have a full body shop with welders, plasma cutter, etc. at my disposal and that is where the jeep will be living until complete.

Currently it is stripped down to pretty much a bare tub, has only drivers seat and dash. I will take some more pictures as the project goes on since I know we all love to watch things unfold.

It has some cancer in the rear frame in the usually spot, however it isnt too bad, once the tub comes off the frame I will rebuild that area using some 1/8th flat bar.

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Unread 02-29-2008, 09:36 AM   #2
pthrift
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there are some replacement floorpan pieces and such you can order....quadratec has them i know; others do to; but IDK where...
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Unread 02-29-2008, 09:40 AM   #3
djcondo
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cool ill look forward to seeing the updates. rusty is doing the same think
http://jeepforum.com/forum/showthread.php?t=395594
this is a pretty cool thred. at least u got the shop.
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Unread 02-29-2008, 09:57 AM   #4
LilViper95
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The jeep came with the pass side replacement floor pan, drivers side has been replaced but it was never painted so its more or less junk. I ordered another from Q-tec. I am going to make up the rear floors out of some sheet metal.
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Unread 02-29-2008, 10:36 AM   #5
rustywrangler
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Quote:
Originally Posted by LilViper95 View Post
The jeep came with the pass side replacement floor pan, drivers side has been replaced but it was never painted so its more or less junk. I ordered another from Q-tec. I am going to make up the rear floors out of some sheet metal.
I feel your pain man. Feel free to ask any questions about working in those areas. I just finished the drivers side with about the same amount of issues and am working on the pass side. See writeup link in my sig. will be more than happy to offer advice. Most of my sheetmetal is 16 gauge from local home centers.

Goodluck

-Rusty
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Unread 02-29-2008, 11:04 AM   #6
LilViper95
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Quote:
Originally Posted by rustywrangler View Post
I feel your pain man. Feel free to ask any questions about working in those areas. I just finished the drivers side with about the same amount of issues and am working on the pass side. See writeup link in my sig. will be more than happy to offer advice. Most of my sheetmetal is 16 gauge from local home centers.

Goodluck

-Rusty

Thank you! I have read through your post a couple times now looking for ideas how others have dealt with this. I do have one question...how did you determine the proper location for the seat belt holes, mine were completely rotted away
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Unread 02-29-2008, 11:13 AM   #7
rustywrangler
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Quote:
Originally Posted by LilViper95 View Post
Thank you! I have read through your post a couple times now looking for ideas how others have dealt with this. I do have one question...how did you determine the proper location for the seat belt holes, mine were completely rotted away
For the front to back location, I just centered it. For the height, I went with enough room off the floor so that I could gain access to the bottom bolt easily. If I had to hazard a guess, they are about 2" off the floor to the bolt center. You could just ask another member on the forum if they could measure for ya but as long as your belt retractor is vertical or a degree or two to the rear, you could mount it anywhere on that section.

-Rusty
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Unread 03-01-2008, 04:36 PM   #8
LilViper95
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Got to do some work on the jeep today. Snowin like crazy here so it was a good day to stay inside! I think I made pretty good progress....This is definately the biggest rust repair I have ever had to tackle!



The hole opened up some once I go the roll bar out!




Drivers side isnt quite as bad.



After cutting out bad metal on pass. side



Bad metal gone on drivers side



Couple of the patches in place (excuse my welds still learning)



This corner is just about done, I used a piece of 1/8th plate on the back side of the seat belt mounting area to give it some strength.



The previous owners idea of a floor patch!!!



After a little POR15....



Day ended a little earlier than I would have liked (ran out of gas in the welder)



OMG....I hadnt been outside since 8am, this is what I was greeted by!
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Unread 03-04-2008, 01:37 PM   #9
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Yay......got the gas filled for the welder....gonna do a little more welding on the floors tonight.

Decided not to replace the pass side floor pan, there were only 2 small areas that were bad so I made up some patches for them. I am waiting for my drivers pan to arrive from Q-tec, hopefully once that gets here I will have the other areas patched so that I can move to the outside panels!
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Unread 03-04-2008, 08:20 PM   #10
LilViper95
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much to my suprise, the ups man paid me a visit while I was at work today!!!! My drivers floor pan showed up from quadra tec.

On a side note I am pretty sure that my Jeep has been rolled over or in some sort of other serious accident in its life, the roll bar mounts on drivers side were all messed up when I took the bar out and the quarter on the drivers side has been replaced, was spliced in about half way through door jamb. Quarter is seriously warped from some poor body work, I am finding more and more areas that need work the further I go. Thank god I dont have much into this and I only bought it for an off road toy....



This is what was lurking under that aweful patch the previous owner installed



Quadra tec pan in place waiting to be welded along with some extra patches to fill in where it didnt cover



Another look at my patches



The patch I made for my seat pan


some patches waiting to be welded!


patch I made and welded into pass. floor pan


quick shot of the frame rust


My half doors, would you believe I was paid $300 dollars to take these!!!! Well not exactly, I purchased two pair and sold one set on ebay for a heck of a profit!!!!
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Unread 03-04-2008, 10:12 PM   #11
minimudder
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wow, nice job on the jeep, your doing a great job of keeping us posted. I was lucky and my jeep doesn't seen to have much rust at all. Nice Write up so far
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Unread 03-04-2008, 10:21 PM   #12
BlackRhino
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I always like following these repair and build threads. I too was lucky with almost zero rust in my Jeep, I don't know if I could handle that much right now.
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Unread 03-05-2008, 10:39 AM   #13
LilViper95
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thanks for the replies!!!! I wish I had a jeep with no rust, but considering how little I have into this rig I really cant complain. I have contemplated selling it once its together and looking for a rust free newer model, but I am sure by the time I get this together I will be too attached!!!!

Hoping to get some more welding done to her this week....I will keep you all posted (my father in law is going to weld the outside panel on the pass side for me so that I dont warp the panel too much!)
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Unread 03-05-2008, 10:49 AM   #14
atomicmoose
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Man, that thing is a project for sure! God's speed to you, sir.
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Unread 03-08-2008, 04:44 PM   #15
LilViper95
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Got to do a little bit of work to the old jeep today, finally got the drivers side floor pan welded into place and top coated with por15.... so now the drivers side is complete, gotta tackle the pass side where the seatbelt and roll bar bolts tomorrow. Hopefully get that completed so I can move on to the exterior panels. This is coming along pretty good! Might be on the road by my birthday next month.
Another plus is I called the ins. company to quote insurance and its only gonna cost me 120 for the whole year!!!!



thats me doing a little welding


some hammering!


the new floor all welded in place!


the welds all ground out ready for some por15



ahhh the finished product!!!!
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Last edited by LilViper95; 04-26-2008 at 05:51 PM..
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