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RIGID LED Light Blowout Sale - All Sizes, All Series, all USA Standard Chromoly Front Axle Shaft Kits with Dana 30 4Stainless Steel Door Hinge Pins

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Unread 10-10-2013, 04:28 PM   #1
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

image-2340712613.jpg

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04' WJ Overland Graphite 4.7 H.O. Quadradrive
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Unread 10-10-2013, 06:41 PM   #2
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
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Unread 10-10-2013, 07:39 PM   #3
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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Unread 10-10-2013, 08:56 PM   #4
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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99' Jeep Wrangler White on White Sport 4.0 Auto
04' WJ Overland Graphite 4.7 H.O. Quadradrive
01' WJ Laredo 4.0 Loaded Quadratrac II
96' ZJ Limited 5.9 mods 242 T-case
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Unread 10-11-2013, 07:16 AM   #5
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!
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Unread 10-11-2013, 07:49 AM   #6
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.
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Unread 10-11-2013, 08:21 AM   #7
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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99' Jeep Wrangler White on White Sport 4.0 Auto
04' WJ Overland Graphite 4.7 H.O. Quadradrive
01' WJ Laredo 4.0 Loaded Quadratrac II
96' ZJ Limited 5.9 mods 242 T-case
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Unread 10-11-2013, 01:02 PM   #8
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)
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Unread 10-28-2013, 06:57 AM   #9
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.
image-1874649716.jpg

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99' Jeep Wrangler White on White Sport 4.0 Auto
04' WJ Overland Graphite 4.7 H.O. Quadradrive
01' WJ Laredo 4.0 Loaded Quadratrac II
96' ZJ Limited 5.9 mods 242 T-case
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