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Unread 12-01-2013, 06:00 PM   #16
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2005 LJ Wrangler 
Join Date: Jan 2006
Location: Mt. Prospect, IL
Posts: 128
Originally Posted by Jason
Disconnect the negative terminal of the battery. Obviously back the heat down a bit to prevent burn-thru. I've seen an article about welding unibodies, but it escapes me right now.
Article is on pirate but I'm having problems finding on my phone. Next time I'm on my computer I'll post the link

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Unread 12-01-2013, 11:19 PM   #17
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1998 XJ Cherokee 
Join Date: May 2010
Location: BC Canada
Posts: 608
Use .030 wire and it's not gonna be an issue. I had trouble when I was using .035 wire, but .030 and it's butter AS LONG as you sand/grind ALL of the sealer and glue stuff off.

This definitely isn't a textbook weld, but it's 3/16" to the unibody, not a problem.

edit: I've seen Kraqa's article about welding on unibodies all over the place. He's actually local to me in the Lower Mainland of British Columbia, active on the local forums, etc etc. He does phenomenal work. His work is clean, well-executed and well thought out. He forgets more stuff in a day than I know about, period. But every time I see that article, I have to disagree about the way he welds on this bracket:

Stitch welding is a great idea. But it doesn't need to be taken to that extreme. Three longer welds on the top side of that piece would have been enough, properly spaced, not 5 miniature welds. With MIG, that's just a bunch of cold starts to me at the beginning of each weld.

Sort of how I did this reinforcement plate for the shock hoops in the rear:
(again, my work isn't textbook either. I eyeballed the lengths of the welds as opposed to marking them off, for one.)
"Chilton's and Haynes are for brake jobs, oil changes and starting campfires." - CJ7-Tim
'98 2dr/5spd Cherokee rockin' on tons, 5.9L V8 Magnum, HP60/14b, 5.13:1, locked, 14" coilovers, Dana 300 4:1 twin stick... oink oink!
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Unread 12-23-2013, 12:34 PM   #18
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1993 ZJ 
Join Date: Jan 2011
Location: chesapeake, VA
Posts: 3,562
Originally Posted by dodger889 View Post
Also ground as close to the welding area too.
This makes a big difference. I ended up using a small piece of plate and tacking it as close as I could to the area I was welding
V8 zj at 6" . Double tri rear and true 3 link front. Stretched to 108"
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