I am new to the forum, and have gained some valuable information during my YJ build. I have only been a Jeep owner for 3 weeks and have been working on getting it mechanically sound.
First, Added the Weber 32/36
Third, Adjust Shift Cable...it's a automatic, turned out to be a job to get it adjusted correctly
fourth, fix all the leaks...transmission, oil pan, and differential
fifth, replace and try to make sense out of all these vacuum lines
I want to thank you all for the information i have gained from this forum...It's running great!
AND NOW, TO ADDRESS THE RUST!!!!
I am not a body shop expert, and really didn't know what i was getting into. I feel it is done to the best of my knowledge and maybe will help someone else.
First thing I did was begin removing the interior
Even though I was focusing on the drivers side only, I removed all the interior to prevent over spray from getting all over it. I also power washed the carpet and seats while they were out.
This is what I found under the carpet on the drivers side. The passenger side wasn't too bad, I was able to to brush the rust off and paint it...
Now to start cutting out all the rust. I cut out small sections at a time, being careful not to cut into something underneath that was good and needed. I used a plasma cutter, but a grinding wheel is just as effective. I chose the plasma so the dust would be limited to under the vehicle and it's quicker.
There are a couple of spot welds on this brace that were stubburn to remove. Be careful not to damage this as it will be needed for your new pan. I used a grinder to remove the spot welds and the remaining old pan came right off...
All the bad stuff removed, now take a wire brush and clean up whats left
It leaves a big hole that would make Fred Flinstone proud
Here is the new pan...ordered off ebay
Made in USA? Not that you can't get quality products made outside the USA, but It was thicker than the original floor, that made me feel a little better about it anyway...
Now to start tacking it into place.. I used a Miller Welder with .035 wire, that's because it's what I had and I have alot of welding experience. I would recomend a smaller wire diameter or you can rivet this in....
All tacked in place. I put a tack about 2 1/2" making sure it was seated well against the original floor pan
Now to sand and prep the surface. I used 400 grit sandpaper to rough the surface on both the top and bottom....NOTE: Sand the underside before welding it in...it makes it much easer.
I was preping not only for future paint, but also the sealer...I wanted the seam to be sealed up tight as to not have problems in the future.
I used Napa Polyester 2 part resin and hardner...I think this stuff did an excellent job for a body filler and also a sealer. I wouldn't be afraid to use it on a cosmetic surface. My friend owns a local franchise and he suggested this to me, he said they have great results from it.[/IMG]
I used Napa Polyester 2 part resin and hardner...I think this stuff did an excellent job for a body filler and also a sealer. I wouldn't be afraid to use it on a cosmetic surface. My friend owns a local franchise and he suggested this to me, he said they have great results from it.
Next, I let the sealer/body filler set for about 30 minutes before sanding. While the top was setting, I filled the under side, while the under side was setting, sanded the top, when I was done sanding the top, the bottom was ready to be sanded. I used 80 grit sandpaper initially, taking it down to about 400 grit..
After getting it all sanded and prepped, I masked some things in the cab, and covered the hood and fenders with plastic and sheets, then spray bomb rustoleum primer.
My jeep is black, so i used black spray paint on the top surface and bed liner spray underneath...
After letting it sit for about 3 hours and everything dry to the touch, I put it all back together...
Good as NEW....
I am not an expert in this field, and know this is not a Chip Foose job, but If you are like me and can't afford to have someone do the work for you, I thought this might encourage or help some of you running around with rusty floorboards that are afraid to tackle this project. I had less than $100.00 and about 8 hours in this repair and feel it will last as long as this Jeep is in service. Thanks again Jeep Forum for all your help. I look forward to getting more involved with this community...