[Fatman]

Ok, so I've been putting this off for a while. But the rust on the Jeep has to GO!

Started pressure washing the muck off a few weeks ago and am in the process of sandblasting the thing clean.

I've got four areas in the floor I'm going to weld in new panels (16 ga) and some rust will be cut out on the passenger side panel.

Also in the body work I'm going to fill every hole that will not be used again, i.e. top snaps, antenna, tire carrier, floor drain holes, and a bunch in the firewall.

So for the next several weeks (I only get to work on this at night and weekends) join me as I rip this thing open and replace pieces of metal.
Feel free to comment, suggest, recommend, whatever with what has worked (or not) for you.

This is what I'm starting with:




Cleaned up a lil bit:




The drivers side has a cheap 20 ga piece of junk that was arc'd in. Going to have to take the cut off to that:


Built a frame to roll the body around on. This helps a lot:



Lots of grime:


Rust is bad, mmm k...:


Future owner work'n hard for the money:

[bdmonist]

What are the coating plans? Herculiner, Line-X, plain ol' paint?

[Fatman]

Got the two rear spots measured up and cut out last weekend.
Also started filling in a lot of the small holes.

Weather has been too nice the last couple of days so I've been riding the Harley to work, but I did pick up a 36 x 48 sheet of 16 ga on Tuesday.
Had them cut it in half for me.

Filling top snap holes:



Tire carrier holes filled:


Laying out for the cuts (used a sawzall on the body):



Cut:

[Fatman]

Originally Posted by bdmonist

What are the coating plans? Herculiner, Line-X, plain ol' paint?

Bottom of tub, firewall, and inside of tub I'm going to spray Black Herc.
Body's going Ford Truck Yellow!

[Fatman]

So the steel came home:


Marked my two rear pieces for the roll bar area:


Few cuts with the 7" cut off blade (thanks BESRK) :


Five minutes with the vice and a 4# hammer & I've got the first piece ready:


Yeah, that's going to work out fine:


I'll bend up the other side tomorrow and hope on Saturday to weld these in place.

[Mr.Crowley]

just something to think about..anytime I weld in steel thats hidden from coating like under that body mount channel I like to spray it with weld through primer..Its a cold galvinizing primer that you can weld through with no ill effects..wont burn with the heat...other than that great job..and good to see you have your son helping you out..times to cherish

[bdmonist]

Saturday's almost over, what gives?

[BESRK]

Looks like you're on the right track. Doing a good job so far. Ditto on the weld-thru primer.

[Fatman]

Originally Posted by bdmonist

Saturday's almost over, what gives?

Patience, patience...

Guys, thanks for the help and suggestions!!!

Ok, Friday (at work) I search the net for this "cold galvanizing primer" and find it at Fastenal. The stuff's not cheep. Confirm they have it in stock, and pick up a can after I get off work. (thanks Scrambled)

Since my family is in Virginia for the weekend I'm not going to hang around, so off to N. Raleigh to help a friend try to bend some 2" pipe for his engine cage. He has some nice steel but his H/F hydraulic bender was not fun to use.
We decide instead to weld some D-ring tabs to his bumper and then add side mounting plates to wrap the frame. Got home bout 12:45 am, misplaced my wallet and finaly crashed.

Today allowed me to get to Lowes, get a new 4.5" grinder, back to the house and then leave with another friend to look at new Electra glide Classics and Street glides in Fayettenam and Ashboro to replace the one he totaled last month.
No luck on the on a replacement, but enough time left in the day to fire up the borrowed sand blaster and make a mess, bend another piece of steel, drill some holes for the roll bar bolts, and spray some zinc primer on the two pieces and the inside of the channels.

No welding on my own rig today, I'll set the two pieces I've got ready tomorrow and weld em in tomorrow once my boy gets home.

Few pics of todays non production:

[Fatman]

With the drivers side cleaned up I pretty much lined up the new piece, set a few pop rivets and welded er up.


One inch fender washers are going to work perfect to fill all of the drain holes:


Pass side lined up, pop rivets to hold front, few tacks and the game is on


Trim the back edge


Cleaned up


Some more zinc primer


Inside tub shots



Tool collection point


My buddy Miller


.

[RnEmOvr]

looking good

[Fatman]

Originally Posted by rnemovr

looking good

Thanks! progress is good.

Few more pics from today:
I filled 7 of these today, the rest I'll have to get once I turn the tub back over:




What a sorry repair the PO did, left the old mess to collect dirt and mud, and covered it with a 20 ga piece of tin.
Cut this out with a nibbler, worked well, nice tool. Going to have to cut out a lot more and remove the repair piece:

[Fatman]

Well we finished sandblasting the bottom of the tub Sunday. (my son's been at wrestling camp, and I have not been motivated) flipped the tub and started brushing on the rust neutralizer. Welded up the top side of the roll bar area repairs and sprayed some zinc primer.

Hope to cut out the front floor boards this weekend and make patterns for the new steel.
More pics soon.

[AggieCJ]

Pretty cool, looking forward to seeing the rest of it come together

[Fatman]

few pics: