Rusty Jeeps , part 1

sarge · 11-07-2009, 11:33 AM

A few months ago I purchased Jon's ( LilblueXJ) 94 2 door XJ as a project for my 16 year old son. I knew it had some rust issues and figured if it was to far gone I would just pull the drive line and sell it to a buddy in need

. Well rust issues are an understatement. A few weeks ago my son called me at work and asked if there was anything he could do to the Cherokee until I got home, I told him to " GUT IT !" he says.... GUT IT ! yep I want it all out, everything but the dash . He did a good job and by the time I got home he was finished and looking a little worried that I was going to part out his Jeep....... So of course like any father would do, I made him suffer while I started screw driver testing the remains of the floor. Then came the Sawsall and this is what I was left with:

for the most part the entire floor of this XJ is gone or on it's way , even in the rear.

I headed to Mitchell's and lucked out , Scott was getting ready to crush an 80's model Caprice. I got the hood and deck lid off it and pealed the sheet metal off the support frames and ended up with enough sheet to do the entire floor for free.

I started the other day and got the front section of the passenger side cut and about 90% welded in.

So I had plans on spending last evening finishing up the front, however, a buddy called with big problems with his 89 YJ. The rear frame was rusted at the shackle and there was only a 1/2 inch strip of metal left at the top of the frame....

So I pulled the XJ out and pulled the YJ in . The frame was completely rusted out around the rear shackle , like they all do. I broke out the Sawsall and the Plasma and ended up here :

I took a piece of 2x5 tube and cut and rewelded it in to something more like 2x4 1/4 , it slid inside the frame and allowed me to weld it and then fish plate it .

Everything fit back together like a glove , I'll get some finished shots this evening.
It was late and I had to work this morning so I kicked everyone out and crashed with out taking any shots.

First thing I said to the wife this morning was " damn I'm sick of dealing with rust !!!!! She responds " ya aint done with Taylor's Jeep yet ! "

Stay tuned for the RUST of the story !

Coppertop · 11-07-2009, 08:58 PM

Nice work...

Nick

carwash · 11-08-2009, 02:04 PM

Ah yes, the rust chronicles.... a book i have read way too much lately.

sarge · 11-15-2009, 08:30 AM

OK ! the rust masking continues . Got the floors in from front to back and got the interior back in. only thing left to do on the inside is a head liner and a good cleaning. no good pics of the inside yet !

on to the outside , this is what was left of the rockers, pretty much nothing :

these shouldn't dent or rust out for a long long time , 2x5 :

welding to the uni-body frame sucks !!!

Ran out of wire late last night so I had to stop with only one side done, I may put a tube step on the rocker at a later date. I am going to fab up some tube flares that will bolt to the rockers and bumpers ( gotta build the rear bumper first.

sarge · 11-18-2009, 09:09 AM

Got the other side completed lastnight ,all except for paint . Now on to the rear bumper and tube flares:

94Dodge Truggy · 11-18-2009, 09:53 AM

lookin good! When is your son taking it to the tressle?

11-07-2009, 11:33 AM	#1
sarge Pure Bacon Join Date: Jan 2007 Location: Trenton, Oh Posts: 1,098	Rusty Jeeps , part 1 A few months ago I purchased Jon's ( LilblueXJ) 94 2 door XJ as a project for my 16 year old son. I knew it had some rust issues and figured if it was to far gone I would just pull the drive line and sell it to a buddy in need . Well rust issues are an understatement. A few weeks ago my son called me at work and asked if there was anything he could do to the Cherokee until I got home, I told him to " GUT IT !" he says.... GUT IT ! yep I want it all out, everything but the dash . He did a good job and by the time I got home he was finished and looking a little worried that I was going to part out his Jeep....... So of course like any father would do, I made him suffer while I started screw driver testing the remains of the floor. Then came the Sawsall and this is what I was left with: for the most part the entire floor of this XJ is gone or on it's way , even in the rear. I headed to Mitchell's and lucked out , Scott was getting ready to crush an 80's model Caprice. I got the hood and deck lid off it and pealed the sheet metal off the support frames and ended up with enough sheet to do the entire floor for free. I started the other day and got the front section of the passenger side cut and about 90% welded in. So I had plans on spending last evening finishing up the front, however, a buddy called with big problems with his 89 YJ. The rear frame was rusted at the shackle and there was only a 1/2 inch strip of metal left at the top of the frame.... So I pulled the XJ out and pulled the YJ in . The frame was completely rusted out around the rear shackle , like they all do. I broke out the Sawsall and the Plasma and ended up here : I took a piece of 2x5 tube and cut and rewelded it in to something more like 2x4 1/4 , it slid inside the frame and allowed me to weld it and then fish plate it . Everything fit back together like a glove , I'll get some finished shots this evening. It was late and I had to work this morning so I kicked everyone out and crashed with out taking any shots. First thing I said to the wife this morning was " damn I'm sick of dealing with rust !!!!! She responds " ya aint done with Taylor's Jeep yet ! " Stay tuned for the RUST of the story !

11-07-2009, 08:58 PM	#2
Coppertop XJWHEELING Join Date: Nov 2007 Location: Colerain Township Posts: 837	Nice work... Nick __________________ Just a 200 dollar cherokee that wouldn't start .. Ten years later same chrome grille ..

11-08-2009, 02:04 PM	#3
carwash pimpin' IS easy Join Date: Jan 2007 Location: Union, KY Posts: 3,344 Images: 605	Ah yes, the rust chronicles.... a book i have read way too much lately. __________________

11-18-2009, 09:53 AM	#6
94Dodge Truggy EX-Vice President Join Date: Jan 2007 Location: Fairfield, Ohio Posts: 3,048	lookin good! When is your son taking it to the tressle? __________________

11-15-2009, 08:30 AM	#4
sarge Pure Bacon Join Date: Jan 2007 Location: Trenton, Oh Posts: 1,098	OK ! the rust masking continues . Got the floors in from front to back and got the interior back in. only thing left to do on the inside is a head liner and a good cleaning. no good pics of the inside yet ! on to the outside , this is what was left of the rockers, pretty much nothing : these shouldn't dent or rust out for a long long time , 2x5 : welding to the uni-body frame sucks !!! Ran out of wire late last night so I had to stop with only one side done, I may put a tube step on the rocker at a later date. I am going to fab up some tube flares that will bolt to the rockers and bumpers ( gotta build the rear bumper first.

11-18-2009, 09:09 AM	#5
sarge Pure Bacon Join Date: Jan 2007 Location: Trenton, Oh Posts: 1,098	Got the other side completed lastnight ,all except for paint . Now on to the rear bumper and tube flares: