Frame Repair Section & Front Crossmember -
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Unread 04-05-2011, 08:07 PM   #1
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1995 YJ Wrangler 
Join Date: Feb 2010
Location: Michigan
Posts: 189
Frame Repair Section & Front Crossmember

I've been logging my progress on my YJ frame repair in the YJ Tech forum, but thought I'd post some of my pics of my first major fabrication project over here.

My 95 YJ had some major frame rot issues, so I invested a little money this year on some equipment and studied a lot of threads, took a couple classes, and practiced on a couple shop projects this winter (cart, small workbench, and a material rack).

Cut off the bad section (front driver's side) and fabbed up a new section from templates I made. The front tubular crossmember was rotted inside the frame so I removed this and made a new one out of 2 x 4 x 3/16 tube after some wise suggestions from the YJ crowd. Just got the new crossmember fabbed and clamped up tonight.

I've really enjoyed reading posts on the fab shop forum and appreciate the talent out there. I'm quickly becoming addicted to the sparks and noise in the shop and looking forward to future projects. Hopefully I don't drive my wife too crazy!

cut-out-parts.jpg   dscn0250.jpg   piece-.-april-3.jpg   assembly.jpg   clamped-jeep.jpg  

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Unread 04-06-2011, 08:23 PM   #2
Rockin jeep
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2000 TJ Wrangler 
Join Date: Jan 2007
Location: Texas
Posts: 8,165
That looks like it will work
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Unread 01-08-2014, 08:29 PM   #3
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Location: Land O Lakes, FL
Posts: 1


I know this thread is pretty old but I hope you can help. I have to replace the front tube crossmember on my '91 yj. Do you have the exact inside frame rail to frame rail measurement? I want to end up with what you have in the pics. Nice job by the way. Any help would be greatly appreciated.

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Unread 01-14-2014, 08:23 AM   #4
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1999 TJ Wrangler 
Join Date: Aug 2013
Location: Lexington, SC
Posts: 29

Well thought I'd add to this instead of making a new thread. Took a stab at some frame repair. I found the drivers side rear section was nearly rotted out when i tried to install a trailer hitch. I bought a safe t cap set off morris and started cutting stuff out. I can say having a cutting torch would have made this easier, but I managed with a cut off wheel. Dropped the gas tank first and put it outside the garage. Also replaced that pesky check valve that was leaking while it was down. I started cutting parts out while my helper scraped the rest of the frame and put some POR15 and internal frame coating from eastwood down. Took about 12 hours, but here it is. Probably the easiest part of the frame to repair since there's just a body mount to contend with for alignment, the bumper holes are predrilled. I put new hardware in sae units instead of metric.
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crossmember , frame

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