KJ rust

[KJowner]

Thought I'd bore you all with the job I was setting up for before my diff decided to play up.
I knew the sills were getting bad but I was hoping to leave them till next summer, no such luck.

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Got a pile of scrap out!

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[KJowner]

Ongoing, but slowly as it keeps raining and my garage is full!

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Polish made outer sill and locally made inner. Lucky I pulled the arch liner out the box section with the spring seat was starstarting to go too.

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Inners I had made from 2mm sheet.

 

[JRB]

Looks nice!

 

[LibertyTC]

Do they throw tons of salt over there? My Jeep was fully undercoated when new.
Salt is such bad news ! Looking much better though.
I often power wash my jeep in winter, to try to keep the rust a bay.
Then spray fluid film, seems to work well on door sills etc.
Next spring I got to do a lot of paint & rust touch ups too!

 

[KJowner]

Yes, they cover the roads with salt all winter, destroys cars. It gets in the structure and rots from the inside out. Yours looks nice and solid, I'm going to clean off the crusty bits, paint then then wax + inject all the bits I can, probably going to take me a few months to complete it as it has to fit in round life!

 

[KJowner]

6 hours of welding and making bits & it's in aluminium primer for the night so it doesn't go orange. More fettling tomorrow then onto the next hole.

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[KJowner]

Next hole...

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And cut out for new metal

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And a new bit let in, wish the whole car was 2mm, its a joy to weld compared to thin bodywork!

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[carcollector]

I took a different route with my 2004 - I put 2006 rocker trim panels on it, and used a seam sealer on the rust rot inside the door (used tape as a mold) - I had to use fiberglass to fill holes in doors and sealer on the door skins down low, used some Bondo to make it a door again and some thick primer, blocked down to 1500 wet to get it straight and ready for a spot blend. I had to cut/trim the front flares and the rocker trim up front but it covered all my rust which I treated with rust converter and primer.

I paid about $30 for trim at junk yard and 2 part epoxy seam sealer was priceless...

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[KJowner]

Looks better done, but the sills are part of the structure so you should really weld steel back it to keep the strength.