The beginning.. the end.... and a fresh start

[GOPBobby]

Don't forget Dora, Peppa Pig, Max and Ruby, all the Disney DVDs, etc. etc... I can't even watch my car shows anymore, the DVR is full of kids cartoons!

cb

True. We just returned from a week of Disney in Orlando, FL and I had about 3% left available on my DVR when I got home. Almost all of it is Disney movies and kid cartoons. I now watch my recorded car and hunting shows and then delete them after my wife and daughter are in bed.

 

[surfjeepzx]

So today I got started on the body work again. I thought my daughters week off would be filled with family activities but both my girls were sick so.... I took the time away from the Jeep and built a swing set, refurbed my buddies go-fast flats boat lower unit, and replaced the water pump on the jeep on my days off. The last two weren't planned but were back burner stuff that got moved to the front. At least it's done now.

 

[surfjeepzx]

Today I finish sanded the grill and sealed it. Now it's ready for paint.

And here is the bulkhead... next in line

The lower flange isn't that bad. It had minor surface rust with one bad spot pictured here. I'll be making a doubler for this area and may do the same for the remainder of the bolt hole locations.

along with welding in a patch plug for this hole and several more.

Aside from the lower flange and filling holes the lions share of the work is straightening out all the dents in the panel. It looks like it was used as a backstop for little league practice. There are also a couple few cracked corners which will get welded too.

 

[surfjeepzx]

The first part of restoring the bulkhead will be all the hammer and dolly work. I'll get the panel as flat as possible. That part is really hard to show with the camera so you'll have to take my word that there's a half day in metal smoothing class 101. Because the bulkhead is visible from both sides I have to make sure I do a neat job to minimize filler use. Once that part is done I'll start welding in the patches and doublers. That will be easier to show with pics.

 

[GOPBobby]

Looking forward to it.

 

[surfjeepzx]

Got a good amount done today. It wasn't that bad and the doulbler idea went well. I cant claim credit for the idea as the corners already are doubled and that's where the idea came from.

I started today by patching holes by tacking some plugs I made in place, grinding smooth, and filling with Duraglass. It's a body filler containing fiberglass and is much stronger than regular filler.

Then I cut some metal from my old tailgate and made the doublers. I bent up the back edge which moved me away from the corner where the metal was pitted prior to sand blasting. It gave a thicker area to weld the plates.

 

[surfjeepzx]

Hmmm. there was another post with a bunch more pics but it seems to be missing. Guess I need to do it again.

 

[surfjeepzx]

This is the bad hole that will get a patch and a doubler. The rest of the holes will get doublers tack welded in place. Although the holes weren't rusted the doubler gives the mounting point strength and will prevent the fastener from deforming the hole as it's tigtened.

 

[cdvcj8]

Nice work This is definitely my favorite build thread.

Although I must admit I was hoping that you would use latches instead, and be the one to show us how it's done right (with pictures of course).

 

[GOPBobby]

Nice work. Mine is in a lot worse shape. I have a couple of 6 to 8 inch sections that are rusted away. I like your technique with the patches. Is it 16ga metal you are using?

 

[surfjeepzx]

Nice work. Mine is in a lot worse shape. I have a couple of 6 to 8 inch sections that are rusted away. I like your technique with the patches. Is it 16ga metal you are using?

Without actually measuring it I'd say the bulkhead is 18 gauge and the tailgate is 16 gauge steel. I'm using metal cut from my old tailgate which is thicker than the bulkhead steel.

 

[surfjeepzx]

Nice work This is definitely my favorite build thread.

Thanks,

Although I must admit I was hoping that you would use latches instead, and be the one to show us how it's done right (with pictures of course).

Latches are a good idea and would be easy enough. I'd probably source them through a marine supply store so they would come in stainless. The downside is that they would tend to be catches for anything that was placed behind the seat. I will end up using 1/4" 20 stainless screws #3 heads that can be spun in and out with a battery drill.

 

[surfjeepzx]

Nice work. Mine is in a lot worse shape. I have a couple of 6 to 8 inch sections that are rusted away. I like your technique with the patches. Is it 16ga metal you are using?

You should be able to use that same technique on a larger scale. It depends on what tools youa have available and if you have any sheet metal hanging around. Ideas for sourcing metal are junkyards, HVAC shops that deal with commercial units. (they would probably have a sheer and a bender that the guy back in the shop could bang out for lunch money).
If you could get the metal prebent nicely then all you need is a sharpie, snips, (a cut off wheel on a cordless drill would even work) Get all the metal cut and formed by hand and ready to weld. Then if you dont know anyone with a welder go to a local muffler shop. They MIG stuff all day long and would probably zap it together once again for lunch money. You'd be surprised but most shops are happy to do side work that walks through the door because it's different than what they're doing every day and it's a chance to earn a few dollars.

 

[GOPBobby]

Thanks for the info. Keep it coming.
Hopefully this rain will get out of N. Alabama today so I can do some work on it tomorrow.

 

[surfjeepzx]

Windshield Frame

So today I finished up the bulkhead and right side fender. That leaves me the windshield frame and then the tub. Next week looks like tub-time.

Here's some pics of the bulkhead and fender in dry time.

 

[surfjeepzx]

here are the W/S frame pics. Up to this point I hadn't touched the frame. The glass was busted when it arrived and there are a few dings around the frame. Someone got happy with drilling holes across the top in addition to the original mounting points.

The plan for this is to have it blasted at the same time I take the tub for sand blasting. I was a little disappointed that when I removed the rubber gasket I found some minor rust spots but nothing that was in the seams. So I gave it the same treatment as the tub. I sprayed Ospho into the seam areas just in case there's some rust hiding out. I kinda have rust phobia so I'm taking every precaution to prevent a future rust bubble popping up.

Both visors were broken but I did save the inserts which were like new.

The dent that broke the window. I didn't have to sweat taking it out.

The gasket looks like new from the bottom but the lip that folds up over the lower edge was weathered so it'll get replaced along with a new gasket and glass.

Some surface rust that managed to poke through in a couple spots. Fortunately I can get to the backside of both areas and it didn't spread.

 

[surfjeepzx]

Well that's all for this weeks episode. Stay tuned for next week when I get overwhelmed with getting the tub to and from the sandblaster, then the prime job that will turn evertything green.. including me.

 

[GOPBobby]

Really nice work!

 

[jims chop shop]

Good work !!

 

[rreed]

Looks like you need new wiper blades too.