Rusty Jeeps , part 1

sarge · 11-07-2009, 12:33 PM

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, 09:58 PM

Nice work...

Nick

carwash · 11-08-2009, 03:04 PM

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

sarge · 11-15-2009, 09:30 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, 10:09 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, 10:53 AM

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

sarge · 11-18-2009, 11:38 AM

couple of weeks till he takes his final test . Oh ..... it's been down there serveal time already

RuffedUpXJ · 11-18-2009, 12:36 PM

You going to have Jeremy or somebody pull him over and scare him silly?

sarge · 11-18-2009, 02:24 PM

Quote:

Originally Posted by RuffedUpXJ

You going to have Jeremy or somebody pull him over and scare him silly?

hahaha , no need . He knows that everyone will be watching ! AND he knows what happens the first time I get a call

RuffedUpXJ · 11-18-2009, 05:05 PM

Quote:

Originally Posted by sarge

hahaha , no need . He knows that everyone will be watching ! AND he knows what happens the first time I get a call

Yeah but it would still be fun. I need to do this to my floors because my carpet is holding it all together.

sarge · 11-18-2009, 05:29 PM

Quote:

Originally Posted by RuffedUpXJ

Yeah but it would still be fun. I need to do this to my floors because my carpet is holding it all together.

The carpet in this one was holding it together as well , I did a late night bonzi run down the creek a was getting hit with water in the face..... and the windows were up

one of my twins was with me and says " Dad why are feet getting wet ????? "

It's all solid (and water tight ) now and has a fresh coat of bed liner .

sarge · 11-27-2009, 05:51 PM

I'm calling this refurb. done for now ! Will get to the back bumper at some point but I have got to get started on my other project

soon . My son is at the BMV as I type hopefully passing his driving test .....

Don't mind the bow tie floor mates , they were in the garage and I figured it would run better with a bow tie in it

already got a little mud on the floors !!

And topped it off with a new headliner .

and some bump in the trunk !

As for the next project ......... here's some hints it will include alot of Bow-Tie (GMC), a little less Ford and a dash of Jeep. Not going to be a huge build or my final wheeler . That one will come later on . This one will be a good all around DD and weekend wheeler sitting on no more then 35's.

Rubi06 · 12-02-2009, 01:44 AM

Looks great! You did what I wanted to do for a long time and never had the time to get around to. Glad someone is getting use out of it instead of seeing it sit around rusting away more.

94Dodge Truggy · 12-02-2009, 07:51 AM

Did your son wreck it yet Sarge?

sarge · 12-02-2009, 11:26 AM

Quote:

Originally Posted by lilbluexj

Looks great! You did what I wanted to do for a long time and never had the time to get around to. Glad someone is getting use out of it instead of seeing it sit around rusting away more.

Thanks Jon , It really has turned out to be a good rig for the boy . I put a set of RE disco's on it the other day and now I'm chasing some electrical gremlins , but other then that it has run great and been beat up at the Trestle a hand full of times.

sarge · 12-02-2009, 11:27 AM

Quote:

Originally Posted by 94Dodge Truggy

Did your son wreck it yet Sarge?

No ...... as I knock on desk !!!!!!!

kingchango · 12-02-2009, 05:06 PM

Quote:

been beat up at the Trestle a hand full of times.

dont let the trenton cops catch you there!!!

biggin69 · 12-02-2009, 06:01 PM

I know the answer to this but I will ask a Trenton Officer anyway. Is it legal to ride at the Tressel? I got a free escort out of there many years ago and have never been back. How do you get in?

sarge · 12-02-2009, 06:31 PM

Did I say the Trestle

who's works for TPD ?

cough ! cough !

Not on a public forum !!!

biggin69 · 12-02-2009, 08:12 PM

I guess there are no Trenton Officers on this forum?

11-07-2009, 12:33 PM	#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, 09:58 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, 03:04 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, 10:53 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? __________________

11-18-2009, 12:36 PM	#8
RuffedUpXJ On XJ 2 Now Join Date: Feb 2007 Location: Fairfield Twp. Posts: 314	You going to have Jeremy or somebody pull him over and scare him silly? __________________ 88 XJ - 5" lift - 35" BFG's - Bumpers - Rock Rails - Homebrewed OBA - Roof Rack - Tube Doors - Trimmed - Dented 87 XJ - D44 - Disco D30 - 235's - 231TC - Stock for now

11-15-2009, 09:30 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, 10:09 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:

11-18-2009, 11:38 AM	#7
sarge Pure Bacon Join Date: Jan 2007 Location: Trenton, Oh Posts: 1,098	couple of weeks till he takes his final test . Oh ..... it's been down there serveal time already

11-27-2009, 05:51 PM	#12
sarge Pure Bacon Join Date: Jan 2007 Location: Trenton, Oh Posts: 1,098	I'm calling this refurb. done for now ! Will get to the back bumper at some point but I have got to get started on my other project soon . My son is at the BMV as I type hopefully passing his driving test ..... Don't mind the bow tie floor mates , they were in the garage and I figured it would run better with a bow tie in it already got a little mud on the floors !! And topped it off with a new headliner . and some bump in the trunk ! As for the next project ......... here's some hints it will include alot of Bow-Tie (GMC), a little less Ford and a dash of Jeep. Not going to be a huge build or my final wheeler . That one will come later on . This one will be a good all around DD and weekend wheeler sitting on no more then 35's. Last edited by sarge; 11-27-2009 at 05:59 PM.

12-02-2009, 01:44 AM	#13
Rubi06 Join Date: Sep 2007 Location: Lebanon, Ohio Posts: 114 Images: 53	Looks great! You did what I wanted to do for a long time and never had the time to get around to. Glad someone is getting use out of it instead of seeing it sit around rusting away more.

12-02-2009, 07:51 AM	#14
94Dodge Truggy EX-Vice President Join Date: Jan 2007 Location: Fairfield, Ohio Posts: 3,048	Did your son wreck it yet Sarge? __________________

12-02-2009, 06:01 PM	#18
biggin69 Really??? Join Date: Sep 2009 Location: Cincy Posts: 678	I know the answer to this but I will ask a Trenton Officer anyway. Is it legal to ride at the Tressel? I got a free escort out of there many years ago and have never been back. How do you get in?

12-02-2009, 06:31 PM	#19
sarge Pure Bacon Join Date: Jan 2007 Location: Trenton, Oh Posts: 1,098	Did I say the Trestle who's works for TPD ? cough ! cough ! Not on a public forum !!!

12-02-2009, 08:12 PM	#20
biggin69 Really??? Join Date: Sep 2009 Location: Cincy Posts: 678	I guess there are no Trenton Officers on this forum?