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Unread 01-28-2013, 06:10 AM   #76
VooDoo2
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Quote:
Originally Posted by acgcoug View Post
Filling in holes from where the diamond plating was installed.

Are you welding this freehand or using a copper/brass backing plate to help with the welds? Ive tried this and blow holes and make the holes bigger or end up with a mountain of metal to grind off.

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Unread 01-28-2013, 09:41 AM   #77
acgcoug
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Quote:
Originally Posted by Matt1981CJ7 View Post
Adam,

I think it may have been easier for you to weld up a new tub from scratch.

I'm enjoying watching your excellent work.

Matt
Lol, thanks Matt

Quote:
Originally Posted by VooDoo2 View Post
Are you welding this freehand or using a copper/brass backing plate to help with the welds? Ive tried this and blow holes and make the holes bigger or end up with a mountain of metal to grind off.
At first I was using a piece of copper pipe that I smashed flat, but then I got pretty good at just filling them in without any backing. So now I just do them all freehand. As long as you have a decent welder and have it set up properly then I think it just takes some practice. When I first started out welding I was putting my settings fairly low because I was worried about blowing through the sheet metal, but my welds were higher and not as nice looking. Now I have a much better feel for my welder's settings, and which one's work well in certain situations. I have my settings higher now and I am getting lower welds with much better penetration. Plus they look better and require less grinding.
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Unread 01-30-2013, 11:16 AM   #78
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I am so glad to see you back in the saddle, Adam, and I enjoy your level of detail. Thanks for taking the time to do such a fine job. It's a pleasure to "watch" you work.
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"Contemplate the mangled bodies of your countrymen, and then say 'what should be the reward of such sacrifices?' ... If ye love wealth better than liberty, the tranquility of servitude than the animated contest of freedom, go from us in peace. We ask not your counsels or arms. Crouch down and lick the hands which feed you. May your chains sit lightly upon you, and may posterity forget that you were our countrymen!" —Samuel Adams

Clay's Build Thread
http://www.jeepforum.com/forum/f8/cl...hread-1061897/
Scott's Build Thread
http://www.jeepforum.com/forum/f8/sc...5-cj7-1147913/
Fallon (and Dad) Build Thread
http://www.jeepforum.com/forum/f11/f...-okee-1445206/
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Unread 01-30-2013, 04:51 PM   #79
acgcoug
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Been getting a few things done here and there.

Now that I'm done with repairing my rear floor boards I can put the factory heat shield back on.

Prepped and coated with 2 coats of Por 15:



Welded back on:



Repaired and cleaned up rear wheel well braces:



Prepping the back side of the braces with diluted phosphoric acid in preparation for Por 15:



First side welded back on:



Other side:



Thanks Scott, I'm glad you are enjoying my build
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Unread 01-30-2013, 08:41 PM   #80
Renegade82
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Looking good. That's the last piece I need to make yet is the heat shield. I have my old one and it has that taper on the corner like yours. I was thinking I cut that, to remove some bad rust. I guess maybe that's it's stock shape after seeing yours. I'll have to look back thru some pics.
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Unread 01-31-2013, 12:37 AM   #81
acgcoug
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Originally Posted by Renegade82 View Post
Looking good. That's the last piece I need to make yet is the heat shield. I have my old one and it has that taper on the corner like yours. I was thinking I cut that, to remove some bad rust. I guess maybe that's it's stock shape after seeing yours. I'll have to look back thru some pics.
Yes, that is the stock shape. I have a second one laying around somewhere and it is exactly the same (off a 1979 CJ7).
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Unread 01-31-2013, 08:12 AM   #82
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Holy Crap! if you two ever get hooked up you could open up the first-ever Dust to Done CJ Shop! You could sell tickets for people just to come and watch ya'll work...
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"Contemplate the mangled bodies of your countrymen, and then say 'what should be the reward of such sacrifices?' ... If ye love wealth better than liberty, the tranquility of servitude than the animated contest of freedom, go from us in peace. We ask not your counsels or arms. Crouch down and lick the hands which feed you. May your chains sit lightly upon you, and may posterity forget that you were our countrymen!" —Samuel Adams

Clay's Build Thread
http://www.jeepforum.com/forum/f8/cl...hread-1061897/
Scott's Build Thread
http://www.jeepforum.com/forum/f8/sc...5-cj7-1147913/
Fallon (and Dad) Build Thread
http://www.jeepforum.com/forum/f11/f...-okee-1445206/
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Unread 01-31-2013, 10:14 AM   #83
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Would you be interested in the marketing directors position? We'd pay you in scrap metal.
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http://www.jeepforum.com/forum/f8/30...e-off-1280850/
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Unread 02-01-2013, 12:19 AM   #84
acgcoug
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My inner spare tire cross-member and braces were in pretty bad condition so I decided to take them out and repair them. Some of the quality of the pics aren't that great, my apologies.

Not a whole lot to see wrong here, but behind the cross-member and the two braces there is a lot of rust.






Cut where the braces are welded to the cross-member, the floor, and cut out the spot welds.





Brace removed











Sandblasted all 3 pieces and coated the backside with Por 15





Sandblasted and painted Por 15 to the mating surfaces



Welding everything back together



Done, and looking much better!

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Unread 02-01-2013, 07:29 AM   #85
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Nice! My POR'ing is at a standstill till old man winter heads back up north! I can do some small stuff if I keep the garage warm a good part of the day, but I don't have any ventilation then. Careful welding beside that stuff. Hold yer breath!
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http://www.jeepforum.com/forum/f8/30...e-off-1280850/
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Unread 02-01-2013, 07:55 AM   #86
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Nice repair job, Adam!

Rich
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Unread 02-01-2013, 02:33 PM   #87
acgcoug
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Originally Posted by Renegade82 View Post
Nice! My POR'ing is at a standstill till old man winter heads back up north! I can do some small stuff if I keep the garage warm a good part of the day, but I don't have any ventilation then. Careful welding beside that stuff. Hold yer breath!
Ah, the benefits of living in sunny California. The Por definitely drys quicker in warmer weather. I've put it on during colder days and the stuff takes quite a while to tack up.

Funny that you should mention holding my breath. I'll lay a short bead, hold my breath, and then step away and direct my box fan toward the area that I just welded. The fumes are definitely awful. Of course I have my garage door open during all this.
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Unread 02-07-2013, 10:22 AM   #88
acgcoug
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Nice little pick up off of E-Bay, 1979 Factory Service Manual. Should be very helpful during my build.



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Unread 02-07-2013, 11:54 PM   #89
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Spent some time repairing the rest of my tub body mounts. I've had to cut out crusty mounts, patch, weld, and make new nut cages (7 total). I can say that I've gotten pretty darn quick at making a factory replica nut cage.








Nut cage plug welded in



How about this nut cage? This is why it can be a pain to get a tub off.



Opened it up and sand blasted the inner rails (just started the blasting on this one). When I'm all done I will coat the rails with Eastwood's Internal Frame Paint.





On to the next two mounts





Sandblasted and slathered some Rustoleum Rusty Metal Primer in these two









Front mount in really bad shape, cracked and smashed down from when the previous owner got in an accident (nut cage removed).



Using the washer trick to pull the steel back up



Before



After is kind of hard to see in the pic, but much better.



Cut out



Finished



Where would I be without these?

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Unread 02-08-2013, 12:03 AM   #90
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I thought I was being fairly thorough! You are going above and beyond! Great looking work
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