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Unread 06-06-2015, 03:21 PM   #1
rwfisheriv
Registered User
1995 YJ Wrangler 
 
Join Date: Jul 2002
Posts: 44
rust/body panel question

As you can see from the photos I'm starting my battle with the dreaded rot. What confuses me is that the body panel seems to be a sandwich, with most of the rust inside. Based on that, how do I approach cutting out and patching? Do I drill a few pilot holes around the rust hole until I find clean metal and then cut out that section? Once that's done, do I just weld on a patch on the outside?


Thanks!!

img_0249.jpg

img_0250.jpg

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Unread 06-06-2015, 05:51 PM   #2
rustisexpected
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1990 YJ Wrangler 
 
Join Date: May 2015
Location: milton, pa
Posts: 146
There never is a simple step by step approach to body panel work. The "sandwich" that you are talking about is common, and fixing it is going to depend on severity. You can pick up a replacement support for the inside fairly cheap. Just cut out all of it that is bad and patch it in. For the outside i would just pick up some 16g sheet metal. Once you have the material to patch you can start exploring. Once you find the end of the rust, square up the hole and make a patch that fits well. If the cancer has spread into your raised jeep letters, and you would like to retain them, then it gets more expensive. A licensed jeep replacement panel is much more expensive than a small piece of 16g sheet metal. Also if it has made its way into the floors you can use the 16g to patch it as well.

If you are going to weld everything in, remember to disconnect the battery and clear away all of the bed liner and undercoating from around the area.

And be prepared you could be opening a can of worms.
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Unread 06-06-2015, 06:14 PM   #3
rwfisheriv
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1995 YJ Wrangler 
 
Join Date: Jul 2002
Posts: 44
Thanks, that's what i was afraid of. I'll get out the tools and start cutting tomorrow. I found a repair panel for a large section (including the logo) but I'm hoping I don't have to cut out that much material...

Seems like an odd place to rust, unless water was coming in through the fender cover bolt.


http://www.classicent.com/jeep/87-95-wrangler-yj
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Unread 06-06-2015, 06:45 PM   #4
rustisexpected
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1990 YJ Wrangler 
 
Join Date: May 2015
Location: milton, pa
Posts: 146
It really is a common spot. Two pieces of metal, face to face, not welded together well, rubbing together for 20+ years... You get the idea.

edit: The shipping on the large panels is where i found the majority of the cost to be. But it does look like all you will need is the sheet metal, and not the raised letters.
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Unread 06-07-2015, 03:46 PM   #5
Que89YJ
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1989 YJ Wrangler 
 
Join Date: Apr 2008
Location: Detroit, Michigan
Posts: 17,964
I have rust there that I need t deal with. Take pics and post them. We can compare notes.
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Unread 06-08-2015, 07:37 AM   #6
fishadventure
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1991 YJ Wrangler 
 
Join Date: Jul 2013
Location: Morrisville, VT
Posts: 1,802
Quote:
Originally Posted by rwfisheriv
...but I'm hoping I don't have to cut out that much material...
One thing I learned on old VWs was that, often, a little bit of rust is just as much work as a lot of rust. As long as the area requiring a cutout isn't bigger than the repair panel there's little extra time involved, relatively, and sometimes "bigger" repairs are easier even if more time consuming. That's all.
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