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Unread 08-12-2012, 07:42 AM   #91
schaef89
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1989 YJ Wrangler 
 
Join Date: Mar 2010
Location: Pittsburgh, PA
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Headed up to the Bantam Jeep Heritage Festival yesterday. Wasn't expecting to buy anything but spotted a guy selling TJ rubicon flares for 10 bucks a piece but was missing a left rear (said it was cracked). I figured what the hell and bought them anyways since I'd only be in it 30 bucks. I left a little after that due to rain but I was pleased w the purchase.

Looked on eBay last night and saw a left rear for sale so I snatched it up. Looks like the YJ will be getting TJ flares if I ever get the floor finished haha.

Couple of the concept jeeps there. Woulda took more pics but kept forgetting

image-3518600693.jpg

J-12

image-3712643744.jpg

Mighty F-C

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89 YJ S, 2.5L/AX-5/NP231
99 WJ Limited, 4.0L/42RE/NP247
93 YJ, 4.0L HO/32RH/NP231 - Sold
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Unread 08-15-2012, 08:06 PM   #92
schaef89
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Well I obviously didn't make my friday deadline because work ended up getting in the way, but I'm back at it this week

image-295493396.jpg

Traced the old panel I cut out

image-3460485030.jpg

Figured I'd try and weld up the seat bracket/nut. I think it turned out pretty well

image-1580357013.jpg

Sprayed with some rust converter after being wire wheeled

image-2339252033.jpg

Trimmed and fit into the gap

image-2244540777.jpg

And welded in. I had to leave a gap there since it was rusted out and the new panel didn't cover it all. I'll cut another piece it fill it up. I called it quits after I took my welding helmet off and realized it was dark out lol
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89 YJ S, 2.5L/AX-5/NP231
99 WJ Limited, 4.0L/42RE/NP247
93 YJ, 4.0L HO/32RH/NP231 - Sold
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Unread 08-19-2012, 06:02 PM   #93
schaef89
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More progress..

image-1481007406.jpg

Cut out a patch and fitted to the panel gap

image-1552217181.jpg

Welded in

image-4135868098.jpg

Seam sealed

image-817096661.jpg

Primered. I wanted to get some protection on these sections because I started to see surface rust form.

On to the driver roll bar area, should be downhill after that part is done
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99 WJ Limited, 4.0L/42RE/NP247
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Unread 08-21-2012, 09:19 PM   #94
schaef89
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Small update since it was a rainy/wet night in the burgh..

I wanted to unbolt the front half of the wheel well plastic to move out of the way of welding.. So I got my TJ flares out to see what kind of tire coverage I would have

image-1376617731.jpg


image-3911847230.jpg

Hopefully wont have much of an issue with inspection

image-3961669492.jpg

Got my tan Rollbar pads on.. Although they are from a 91 and the seatbelt holes are about two inches off : I'll have to figure out how to handle that later on.. Maybe glue some fabric from behind of similar color. I just put my grab handles and extinguisher on to get them off of shelves for now until I figure a solution

image-2464593223.jpg


image-3410620644.jpg

Hole is just under my thumb.
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89 YJ S, 2.5L/AX-5/NP231
99 WJ Limited, 4.0L/42RE/NP247
93 YJ, 4.0L HO/32RH/NP231 - Sold
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Unread 08-22-2012, 06:45 PM   #95
schaef89
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So it's time for the worst of it...

image-2611335816.jpg

After wire brush

image-1586494086.jpg

After the hammer

image-1522887423.jpg

Got the bad cut out.. More to come on this


Side note.. Does anyone know the size bolt for the gas pedal mount?? I seemed to misplace one. Pictured below

image-3451747969.jpg
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93 YJ, 4.0L HO/32RH/NP231 - Sold
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Unread 08-22-2012, 07:02 PM   #96
pete1991YJ
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Quote:
Originally Posted by schaef89 View Post
So it's time for the worst of it...

Side note.. Does anyone know the size bolt for the gas pedal mount?? I seemed to misplace one. Pictured below

Attachment 458069
If it took a 1/2 inch wrench then its 5/16-18. *Most* of the jeep body is this size. If it took a 7/16 wrench then its a 1/4-20. Hope this helps. PS thats some impressive rust yer dealing with there... it reminds me of work
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Unread 08-22-2012, 07:26 PM   #97
schaef89
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Quote:
Originally Posted by pete1991YJ

If it took a 1/2 inch wrench then its 5/16-18. *Most* of the jeep body is this size. If it took a 7/16 wrench then its a 1/4-20. Hope this helps. PS thats some impressive rust yer dealing with there... it reminds me of work
Thanks pete.. I was thinking 1/4-20 myself. I just wanted to pick everyone's brain to confirm my guess

And I'm definitely getting surprised w how much rust it has as well
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93 YJ, 4.0L HO/32RH/NP231 - Sold
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Unread 08-26-2012, 02:51 PM   #98
schaef89
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Update after this weekends activities..

image-2350072915.jpg

My support channel was a little worse for wear so I cut out the bad parts and welded in new

image-2466652400.jpg


image-606666082.jpg


image-3732086300.jpg

Fixed. And also got this so I don't catch myself on fire since I was welding directly over fuel lines

image-3680934809.jpg


image-4293143552.jpg

Rust converter on the channel

image-729819723.jpg

First piece welded in

image-2127301243.jpg

Fully welded in

image-1573567866.jpg


image-1596585327.jpg

Seam sealed and primered.

Glad to have the worst out of the way. Passenger side is next!
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Unread 09-05-2012, 06:33 PM   #99
schaef89
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Update time.. Passenger side Rollbar footing

image-3895564602.jpg



image-2347604003.jpg

the lady wanted to help



image-3172184949.jpg



image-3479838026.jpg

Had to bend up a piece of 16 gauge since I didn't buy a replacement panel. Not too bad for only having a bench vise I think


image-2881081929.jpg

Welded

image-2971511895.jpg


image-2519352902.jpg

Seam sealed and primered
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Unread 09-05-2012, 07:34 PM   #100
jresch10
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This thread ROCKS! I bought an '89 YJ a few weeks ago and I'm going to have to replace the drivers side floor pan and the section where the left side of the seat riser mounts as well. I also have a section in the rear right corner of the floor back by the tail gate to replace. Never welded before in my life but I think I can learn. Thanks for the thread!
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Unread 09-06-2012, 07:23 AM   #101
schaef89
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Quote:
Originally Posted by jresch10
This thread ROCKS! I bought an '89 YJ a few weeks ago and I'm going to have to replace the drivers side floor pan and the section where the left side of the seat riser mounts as well. I also have a section in the rear right corner of the floor back by the tail gate to replace. Never welded before in my life but I think I can learn. Thanks for the thread!
Thank you sir. I actually haven't welded much of anything previous to this jeep rusting out (besides a semester course in hs). But it's def a learning process for me and I hope to get better as I go. Good luck with your floor!
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Unread 09-06-2012, 08:24 AM   #102
jresch10
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Are you using flux core or MIG?
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Unread 09-06-2012, 08:42 AM   #103
schaef89
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Hobart flux core (MIG capable)
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Unread 09-06-2012, 01:21 PM   #104
Paranoia55
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Hell yeah another 89
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Unread 09-06-2012, 06:57 PM   #105
schaef89
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Last bit of rust..

image-3426645068.jpg



image-3480744572.jpg



image-3450876723.jpg



image-3319991204.jpg

Cleaned up for sealer and paint

image-1991492390.jpg

And this means the floor is 100% completed! I will celebrate with some relaxation a few of these

image-105904062.jpg

so pumped its done.
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99 WJ Limited, 4.0L/42RE/NP247
93 YJ, 4.0L HO/32RH/NP231 - Sold
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