Overland advice - JeepForum.com

 
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post #1 of 9 Old 10-10-2013, 04:28 PM Thread Starter
Bandit84
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2004 WJ 
 
Join Date: May 2008
Location: MN
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Winters around the corner and I'm trying to get my 04' Overland prepared. Here's my first question. On my rear driver side rocker has developed rust under the cap cover where the rock sliders are. This seems to be the only spot that seems the worst. I'd like to either sand it down and Por 15 it or cut it out myself and weld in some sheet metal. I do have some welding practice and I have a 90amp flux welder. Or should I wait til spring to have the rocker replaced in the spring. If I do it myself, any advice or tips? Thanks for your help. Bo

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post #2 of 9 Old 10-10-2013, 06:41 PM
ZJPunk98
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Cut it out, clean the inside as much as possible, then coat with POR-15. when the por is dry, weld on some new metal and paint it up. There are several custom rocker fixes posted here which incorporate rock sliders. You should check that option out.

edit: check out my build as a reference http://www.jeepforum.com/forum/f197/...38/index2.html

Erik

98 ZJ 5.2L JGC Limited Sold
02 4.7L HO JGC Overland
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post #3 of 9 Old 10-10-2013, 07:39 PM
Duh
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On my rockers i sanded them down and put on some rustoleum rust reformer, bondoed the holes and primed/painted . Looks fine. Only time will tell how well it worked.
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post #4 of 9 Old 10-10-2013, 08:56 PM Thread Starter
Bandit84
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I'm just wondering if my welder is adequate for the job. That's my main concern. I'd like to just patch that area, cut and grind the rust, clean and Por 15 the inside, then spot weld the new piece in and smooth it out for paint. The welded in sliders are nice but I'm not sure if I wanna go that route yet.

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post #5 of 9 Old 10-11-2013, 07:16 AM
cubalz
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Wait until Spring and then cut it all out and weld in fresh metal. I will tell you this: The rust will most likely be worse than you imagine once you dig into it. Once you cut the outer rocker skin off, the inner typically is in varying degrees of bad too. I had these problems on my 02 GC and i live in Delaware where we hardly ever get snow and I just cut out and replaced 85% of my lower inner and outer rockers. It is a bad design that we all have to live with. Good luck!

2003 Rubicon - 33x12.50x15 GY Duratracs, 15x10 MT Classic Locks, 2" BL, 2" BB, Warn Front Bumper, Garvin ATS Rear Bumper, Body Armor Extreme Rock Rails, Nth Degree Tummy Tucker, Skid Row Engine, LCA and Gas Tank Skid Plates, Teraflex Quick Disco's, Uniden Pro 520xl CB, 3' Firestik Antenna, BW Flat Fender Flares, Tom Woods DS, Currie Rear Adj Arms
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post #6 of 9 Old 10-11-2013, 07:49 AM
gold01wj
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Don't use the flux welder if you don't have too... Flux cored wire + body work = very frustrating time. I tried this route when doing cab corners on my 57 chevy... Will never repeat that mistake again. Flux core is good for heavy structural steel but for thin-ish sheet metal it's harder to control and i found more prone to warping. not to mention all the slag chipping is a pain too.

2000 wj limited quadradrive 4.7 family vehicle-was stock, then lifted 4",now stock again
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post #7 of 9 Old 10-11-2013, 08:21 AM Thread Starter
Bandit84
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What would you recommend for a welder? I see Lincoln has a Small Mig welder in my budget.

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post #8 of 9 Old 10-11-2013, 01:02 PM
gold01wj
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For what your trying to do, a small mig is ample. Doesn't need to be anything fancy. Miller and Lincoln are both decent brands. I personally have a small Lincoln for these kind of projects that works great. it uses a normal electric plug which is nice. If you can spring for the Lincoln jump on it. If you don't already have one you'll need the bi-mix gas bottle as well (argon & co2)

2000 wj limited quadradrive 4.7 family vehicle-was stock, then lifted 4",now stock again
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post #9 of 9 Old 10-28-2013, 06:57 AM Thread Starter
Bandit84
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Well I did some work on it this weekend. I cut out a small section of the rusted area to see what I was up against. It's def not terrible, I was able to sand it down and Por 15 that area good after I got all the foam out.

I'll probably put some metal tape over it til spring and then weld a patch there and sand bondo and paint. The rock slider cap sits there so that'll hide and imperfections.
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