We got it running alright (pretty good actually) after we replaced the rotten gas tank, added new fuel and filter, replaced broken vacuum lines, and set the idles. Man did the PO screw up the vacuum lines, what a job mapping those all out! We also were getting poor performance before we realized we had grounded the high altitude jumper wire.
It doesn't look too bad at first glance but it has A LOT of rot. Before taking the body off the chassis we decided to sure up the tub and do some rot removal. We didn't start taking pictures right away but these are from pretty early on.
The windshield post was rotted most of the way through, so we cut it out and fabbed our own to match the original.
Last edited by 85JeepinCJ7; 04-27-2009 at 10:57 PM..
Once we started rot picking there was no going back! Drivers side floor was rotted pretty bad (has a full rollbar, and the mounts rotted out where they attached to the floor). Same thing with the drivers side floor, rot city. There was a moment we thought about buying a tub... until we saw the price, lol.
Here you can see some of the floor work, repaired seatbeld structure/brace, and wheel well work. The drivers side door wouldnt even close, the jams were so rotted out the whole side wall would shake when you slammed it.
The rocker panels had rot holes. The rear quarter panel had been dented and filed with bondo. The driverside floor had rotted up the side and *almost* ate up the jeep stamp. We almost werent able to save it. After asking ourselves wether we should cut our losses and just fill the holes we went for it... drilled out the spot welds and cute out the dead material. We traced the holes onto cardboard and transfered the markings to the sheet metal.
After cutting out the sheet metal all the contours were made using a hammer and dolly block.
Tacked up the rear panel...
Cut out and tacked up the rocker....
Saved the jeep logo... a close one
Last edited by 85JeepinCJ7; 04-29-2009 at 08:57 PM..
What kind of rust proofer do you guys suggest that wont interfere with the welds? We hit a few spots with rustoleum (in the never to be seen again areas) but it seems to hinder the welding process.
I've had good luck with weld through primer. Most welding jobbers keep this stuff on hand. Nice fab work. JC
80 CJ-7 Straight six,comp cam,4.0 head, cherokee header, DUI distributor, Affordable FI TBI ,4.10's wide track amc 20 aussie locked and trussed, Dana 30 aussie locked, PSC steering box, 4.5 RE lift, twin sticked dana 300 with Lo max 4to1 35"STT'S ON DC-1 "It's getting there"
Thanks guys! Maybe one of you CJ vets can help me out with something... The drivers side door has some rot in the window frame. Know if/where i can buy just a replacement window frame? Looks like a tough repair job. Anyone have any photos of their own window repair?