Surprise your jeeps new again - JeepForum.com
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post #1 of 238 Old 06-15-2011, 12:36 AM Thread Starter
kphimself
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Surprise your jeeps new again

Someone really special to me thats in the navy went on deployment so i decided that instead of her jeep bleeding out and leaving piles of rust on my driveway i would give her a bit of a surprise and fix it up. The first thing that needed to be repaired is the complete lack of a rear frame. I have no idea how this thing didn't fall apart going down the highway. I spent yesterday removing the rear suspension, axle and gastank. The only thing that wasn't rusted apart was the gas tank. I think chrysler should look into making the whole jeep out of plastic. I also liked the random metric bolts becouse its so much fun to keep climbing out from under it to get a new wrench. Once i had the axle out i found the source of one of the many oil spots on my driveway, the brake like was rusted away. I replaced the rear brakes and made new lines for it, cleaned and repainted the axle. I'm buying time till the new frame repair sections come in. I don't want to get to ahead of myself since i have a lack of space in my garage. i'd prefer to have the rear of the vehical put back togther before i start trouble shooting the oil leaks that are coming from the front of it.

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axle.jpg   shocks.jpg   axleprimer.jpg   axleprimer2.jpg   rearframepassengerside.jpg  

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post #2 of 238 Old 06-15-2011, 12:37 AM Thread Starter
kphimself
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More pics
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post #3 of 238 Old 06-15-2011, 02:11 AM
hartke20g
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this is a great thing you're doing for your deployed friend. major props for taking the time (and money!) to do this for someone putting their life on the line.

maybe seeing this thread will show my buddy that you can repair rusted things (like his el camino) with just a bit of time and elbow grease.

1998 TJ 4.0 Sahara, D30/D35, 33x12.50x15 Mud Kings, HF 8k winch, snorkel. "Military Edition"
BLS33: "Granted in general I am all for kicking babies, but in such an instance it would seem unfair, I would kick the parents first."
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post #4 of 238 Old 06-15-2011, 02:37 AM Thread Starter
kphimself
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Thanks
This really isn't too bad of a repair, My project car needed the entire center of it replaced and it is a convertable unit body car, that sucked. Like you said as long as you take your time and be careful not to overheat and warp sheet metal you can end up with a great final product. Tell your friend don't be scared, just make sure his tetanus shots are up to date.
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post #5 of 238 Old 06-15-2011, 09:04 AM
schaef89
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love this idea Good Luck!
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post #6 of 238 Old 06-15-2011, 02:12 PM
wrscpc07
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that's awesome! Very nice of you, that's one lucky friend you got there

97 Tj 2.5 4" skyjacker 1.25 JKS BL. 35x12.5x15 8.8 w/ 4.88s
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post #7 of 238 Old 06-15-2011, 11:36 PM Thread Starter
kphimself
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I didn't get to take my nap after work this morning so i didn't get much done. I was able to repair the cracked doors mainly cause I felt melting some metal. Its going to be great to finish the rust repairs and body work and get to the fun part.
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post #8 of 238 Old 06-16-2011, 01:50 AM
bhblaine
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good for you! that is awesome

"Dude, just sell plasma, sperm and blood. Thats what you have to resort to while in the process of a jeep build. " -BHBlaine
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post #9 of 238 Old 06-21-2011, 03:13 AM Thread Starter
kphimself
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While i was waiting on parts I decided to fix a dent in the door that was bugging me. I didn't have one of those cool dent pullers and i didn't wanna use a slid hammer so tacked some 10 penny nails to it and pulled them, worked like a champ.
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post #10 of 238 Old 06-21-2011, 09:54 PM Thread Starter
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Today was another day of rust removal. I guess the frame repair panels are on backorder or something so i don't know if i'm ever going to get to melt some metal. I got the doors dent fixed and wetsanded. I am really surprised how well using the nails to pull out the dents worked, i may try this little trick out on the rear fuel panel. I was planning on replacing it but if i can save 75 bucks im game for that.
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post #11 of 238 Old 06-22-2011, 07:18 AM
schaef89
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I think this thread is in need of some more pics..

Good work so far!
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post #12 of 238 Old 06-22-2011, 07:41 AM
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Nice . more pics
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post #13 of 238 Old 06-23-2011, 09:34 PM Thread Starter
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I got up today and found my frame repair panels sitting on my patio. Not 5 mins later i was in my garage clothes ripping that box open like a kid on christmas day. I started off by taking some measurements and removing the angle iron that was half welded on and as much of the rotting metal as i could. I then sprayed some PRO-15 as far in the frame as i could reach. while i was waiting for that to dry i went to the store and got some welding wire and had my gas tank filled, nothing worse the running out of either in the middle of a project and having to wait till the next day to finish up. When i got back i coated the inside of the frame and the area that the repair panel would be covering with some weld thru primer. I thought it was gong to be a pretty cut and dry install, not so much. I was hoping that the holes in the repair panel would match the holes in the frame but as soon as i test fit it i realized that was not the case. This is why you always measure twice before cutting. After i made some adjustments to the panel and measured it like 10 times i welded it in. I did the same process on the other side as well. I was very happy with how it came out. I gotta give ARS credit for a making an awsome product, even though it needs a little fine tuning but what fun would it be if things just went together without a hitch.
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265653_2091984547994_1496682546_32295096_2859158_o.jpg   259190_2091987148059_1496682546_32295098_6890031_o.jpg   257124_2092065550019_1496682546_32295196_6156792_o.jpg   258108_2092030869152_1496682546_32295139_7463578_o.jpg   258318_2091993188210_1496682546_32295106_682800_o.jpg  

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post #14 of 238 Old 06-23-2011, 09:57 PM Thread Starter
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So now that the jeep is no longer a highway bomb its time to move onto the suspension. I ran the numbers last night and the difference between getting new shocks, bushings, brake lines, u bolts ect... is about $180 less then doing a 2.5inch lift. So i think the logical thing to do is a lift. So i guess ill start on the body work to keep me busy till payday. I promiss to post more pictures as i make progress.
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post #15 of 238 Old 06-23-2011, 11:12 PM
89Jeeper
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Wow this is gonna be fun to follow! good luck!
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