There’s been a lot of work being done on my fathers super rusty Jeep TJ. I used it as an excuse to buy a welder and then I got to work.
Before: there was pretty much no frame left, I stepped on the gas and broke one rail into two pieces.
After: New frame cut down to thick good metal and new patch plates welded in. This was way more work than I anticipated. Body mounts still need to be repaired, and I’m going to bridge any remaining holes between patch panels with some flat stock.
Fenders were rusted through entirely so we installed new fenders. They are crazy cheap Chinese stampings that are oddly really nice in quality. To come is a full paint with smooth white bed liner.
There were some big holes in the body corners and arches so I cut patch panels out of the old fenders. Not great, but grinding and thick bed liner paint will hide my lack of skill.
Also not pretty was a full floor pan I welded in, the rust exceeded the area covered by the new floor pan so I had to use metal cut out of the old tailgate as a bridge patch. Luckily this will all be hidden by dynamat and carpet.
Jeep goes to the mechanic this week for all new brake lines and rear drums, also probably new steering tie rod ends.