Rust hole through body-how to fix?? - JeepForum.com

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post #1 of 18 Old 02-27-2004, 12:30 PM Thread Starter
JEEPINWI
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Rust hole through body-how to fix??

Hey Guys~

I have had some rust spots surface over the past couple years, but one has finally gone all the way through the body. I will post a picture by tomorrow. It is on the driver's side rocker panel and about 2" around. What would be the best method of fixing this problem and keeping it from returning? I have already ordered some Por-15, but what else should I use to fix/fill this permanantly? Any links for info on repairing rust would also be appreciated. Thanks.


Brian-
99 XJ Cherokee, 2 door, 4.6L Stroker, 5 speed, 4x4, 8.25" rear, 3.07 gears
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post #2 of 18 Old 02-27-2004, 03:24 PM
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Do you want to fix it or stop the rust and hide the area?

Fixing back to look original it is gonna cost some bucks. You will have to cut out the spot and patch it, then have the whole panel painted.

Hiding it is the best option. Cut and grind out all the rust, then POR 15 it. Then the fastest hiding job is to bolt on some diamond plate rockers. Another option it to Bondo or Fiberglass up the whole and paint your rockers with something textured like Heruliner to hide you patch.
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post #3 of 18 Old 02-27-2004, 03:43 PM
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Quote:
Originally Posted by JEEPINWI
Hey Guys~

I have had some rust spots surface over the past couple years, but one has finally gone all the way through the body. I will post a picture by tomorrow. It is on the driver's side rocker panel and about 2" around. What would be the best method of fixing this problem and keeping it from returning? I have already ordered some Por-15, but what else should I use to fix/fill this permanantly? Any links for info on repairing rust would also be appreciated. Thanks.
If you are not a welder and cant use sheet metal.....just grind or cut out the bad spots (make sure you get all of it or it will come back) then put some fiberglass cloth behind the area you cut out. Once the fiberglass dries....you can bondo on top of that to smoothe the area out.

If you have never tried this before and are intimidated about doing so.....DONT BE! It is REALLY EASY!

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post #4 of 18 Old 02-27-2004, 11:58 PM
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welding

i had alot of leftover holes in my floorboards from the original owner. i welded them up and it worked great. id suggest cutting out the bad metal. id be agressive and cut out at least an inch into what appears to be good metal. id then weld in a piece of sheetmetal. if you dont have a welding machine you probably could rent one. homedepot has a decent manual on welding with some good info. if you use bondo make sure to prime the metal first. when bondo is setting it can get condensation inbetween it and metal. best to stay away from bondo though, has a habit of cracking while offroading
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post #5 of 18 Old 02-28-2004, 12:03 AM
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Quote:
Originally Posted by fratis
i had alot of leftover holes in my floorboards from the original owner. i welded them up and it worked great. id suggest cutting out the bad metal. id be agressive and cut out at least an inch into what appears to be good metal. id then weld in a piece of sheetmetal. if you dont have a welding machine you probably could rent one. homedepot has a decent manual on welding with some good info. if you use bondo make sure to prime the metal first. when bondo is setting it can get condensation inbetween it and metal. best to stay away from bondo though, has a habit of cracking while offroading

Use Evercote Polyester Body Filler..........it is 1000 times easier to sand than Bondo and will never crack!

1990 YJ, 258 w/ weber carb, HEI upgrade, 3.5" springs, 2" body lift, 1.5" shackles, TJ flares, Eagle 118 15x10" wheels, Rocker guards, 35x12.50x15 GY MT/R's, Lockrite F/R, POSI-LOCK, Dual Batteries (optima Red/Optima Yellow) Bestop Super Seats, 9000lb Superwinch, Custom bumpers w/ swingout tire carrier, and Rockford Fosgate for my listening pleasure!

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post #6 of 18 Old 02-28-2004, 12:19 AM
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if you do want to go the welding route and depending on where and how bad the rust is, you might want to get replacement panels from quadratec. they have preformed weld-in replacement for just about the entire interior. they're all under 50 bucks and might save you some aggravation.

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post #7 of 18 Old 02-28-2004, 04:46 AM
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Save your money and patch it

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Last edited by GEAH; 02-28-2004 at 04:52 AM.
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post #8 of 18 Old 02-29-2004, 12:00 AM
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Here is a link to a guy that did some work with the bondo. Looks pretty straight forward.

http://www.jeepz.com/modules.php?op=...=body_bodywork

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post #9 of 18 Old 02-29-2004, 09:01 AM Thread Starter
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Here's a link to the page where I have a pic posted. Jeep Rust . It's not actually a pic of my Jeep, but exact same rust spot. Scroll down a bit and it's pic #11

I have access to all the equipment to permanantly repair the rust, but never had to fill in any holes. I like the idea of using the fiberglass patch then going over it with the Evercote Polyester Body Filler. I am a little intimidated by the welding as this spot is quite noticeable and although I am a decent welder, I don't feel I could get a smooth finish.

Brian-
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post #10 of 18 Old 03-05-2012, 10:12 PM
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Quote:
Originally Posted by saint152 View Post
Use Evercote Polyester Body Filler..........it is 1000 times easier to sand than Bondo and will never crack!
Would the 'Lite Weight' do, or the 'Kitty Hair' one?
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post #11 of 18 Old 03-05-2012, 10:23 PM
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Originally Posted by idskot View Post
Would the 'Lite Weight' do, or the 'Kitty Hair' one?
Dusted the cobwebs off this thread I see... Necrothreadillia is the term I believe I heard for just this occasion. Kidding aside I'm sure someone will get around to your question.
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post #12 of 18 Old 03-06-2012, 09:30 AM
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Dusted the cobwebs off this thread I see... Necrothreadillia is the term I believe I heard for just this occasion. Kidding aside I'm sure someone will get around to your question.
OH! Wow. I didn't even bother checking the year, thought it was last posted 2 days ago!
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post #13 of 18 Old 03-06-2012, 09:44 AM
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I know, old thread. but here is my 0.02 anyway...

Bondo is for show cars, not trail rigs and DD jeeps.

They call me the King of Fun! Everwhere I go I hear "Here comes that Fun King MegaCabMan"
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post #14 of 18 Old 03-06-2012, 10:12 AM
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Quote:
Originally Posted by MegaCabMan
I know, old thread. but here is my 0.02 anyway...

Bondo is for show cars, not trail rigs and DD jeeps.
How do you suggest I fix a bubbling rust spot?
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post #15 of 18 Old 03-06-2012, 12:22 PM
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Quote:
Originally Posted by sentinal02 View Post
if you do want to go the welding route and depending on where and how bad the rust is, you might want to get replacement panels from quadratec. they have preformed weld-in replacement for just about the entire interior. they're all under 50 bucks and might save you some aggravation.
I debated getting those when I had to replace and repair my rocker panels. Issue was I didn't really know how large they were or how much they actually covered. Its very hard to tell from their website. So i took some careful measurements and had my local steel supplier shear me the right size plates for my repairs. Cost me 30 bucks total for both sides. And I did the ENTIRE rocker front to back. Search my username and you should find the rust repair thread I did detailing the repairs. It was a pain but well worth it.






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