FOLLOW UP: Rust Removal DONE! (Pics/Story inside)

dingus

dingus

Active member
RE: cherokee console removal

Well after a long week of working on this bad boy (not 8 hours a day or anything...) the old rusty floor was cut out and galvanized steel was welded in place. i just got done fiber glassing where the welding wouldn't work (metal too thin) and primered it all over.

I HATE RUST!

once she's all dry i'm gonna undercoat the $h!t out of all this mess. what a project but i'm glad it got done right.

PICS:
http://natecovington.com/ipw-web/gallery/rust


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time for a shower and a margarita,
-Nate
 

Master Cylinder Leaking

Well done :) Glad you stuck with it and de-rusted the beast...

I fear the day that mine gets that bad, just waiting for the carpeting to finally wear out so I can rhinoline the inside or something...
 
RE: cherokee console removal

oh yeah... i wanted to mention... the guy who welded for me (the older guy in the pics) is a true jeeper! hats off to him!

his daily driver is a 97 Grand Cherokee, also has a CJ5 w/ 90k miles as his plow vehicle and an '85 XJ w/ lift n tires 5 speed sittin around his house too. what a guy!

edit: i forgot to tell details...

we cut out all the rotted metal with cutting wheels and grinders. we used galvanized 14 gauge steel and tacked it in with a MIG welder. then he ran bead all around everything, except just a few areas i touched up with fiberglass. i also put fiberglass resin all over the welds themselves just to seal them in. when that dried, i primered everything, top and bottom. when that dried, the bottom got undercoated with spray-on undercoat. tomorrow i'm gonna put the carpet and seats back in. TADA!

-nate
 
RE: Dumb question

Wow, nice job nate.

See, now it's MORE personalized. It's your XJ for real now.
 

Great job, great looking repair!

I hope the guy welding used a fan and did not breath the fumes from the galvanized metal. That stuff is deadly toxic :cry:

Smart move on sealing the weld seams even.
You will have something you can be proud of, I can't believe you got it done this fast!!

90
 
RE: Best lift to get?

So you should be able to get it inspected now, right?

It will seem like a better deal when it's on the road ;)
 

she just needs a cracked exhaust manifold fixed (either replaced or welded) and the headlights to work... (low beams wont work, high beams do...) then she's ready. i can't wait to be able to drive LEGALLY! lol
 
90Xjay said:
I hope the guy welding used a fan and did not breath the fumes from the galvanized metal. That stuff is deadly toxic :cry:90
Click to expand...

I hope so too. A freind of mine woke up 2 days later after welding that stuff. Sick as a dog and lost all is hair. He's now bald, but not by choice. Zinc is nasty stuff.

Looks good though! :D
 
Nate,
Don't waste your money or time trying to weld up that manifold. The factory ones are made from thin wall material and are hard to weld and make a good repair that will last.
Look around the net and you can find a good stainless manifold for $150, some are even reinforced in the stress areas, but I can't comment on those, I have not looked at one up close.

90
 

RE: high beams work, low beams won

well the manifold crack was pretty accessible, he (same guy, i found out further that he's actually CERTIFIED as a welder, so even better. he patched it up real nice and it will pass inspection. if it breaks again i'll try something different, but for now i'm taking the cheap way out.

nate
 
RE: Cross Drilled or Slotted

as far as welding the manifold, if we're talking 6 cyl of course... I just repaired one to be installed. I used a piece of 1/16"x1"x6" flatstock to weld along between the pipes to keep them sturdier. It might be the end to it cracking. I hope
 
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