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Rust Assessment And Opinions

Discussion in 'Builds and Fabricators Forum' started by Aidan Turner, Jun 24, 2020.

  1. Jun 24, 2020
    Aidan Turner

    Aidan Turner New Member

    Morristown, NJ
    Joined:
    Jun 19, 2020
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    41

    I did some rust assessment today and this is what I’ve discovered. I’m curious to see what you guys think of it. I’m up for the challenge of welding in panels but I want the opinions of more experienced people.
     
  2. Jun 24, 2020
    Jw60

    Jw60 I don't do metric 2024 Sponsor 2023 Sponsor 2022 Sponsor

    Trails end,...
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    Measure often, write everything down. Take pictures and Maybe take a video. Otherwise you may go to put a hardtop on and find the bed to be 1/2" short on one side
     
  3. Jun 24, 2020
    durangotang

    durangotang Member 2022 Sponsor

    Not Western CO
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    Is there a picture? I can't see one.
     
  4. Jun 24, 2020
    Aidan Turner

    Aidan Turner New Member

    Morristown, NJ
    Joined:
    Jun 19, 2020
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    There should be 7

    Here is a link just in case.

    Rust
     
  5. Jun 25, 2020
    FinoCJ

    FinoCJ 1970 CJ5 Staff Member

    Bozeman, MT
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    Looks like a lot of work and body removed from frame to access all sides? As it appears to be mostly the floor, maybe not ridiculous? Floorpan and hat channels from classic enterprises.
     
    Aidan Turner likes this.
  6. Jun 25, 2020
    Keys5a

    Keys5a Sponsor

    Florida Keys
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    I didn't realize it, but you have a Tuxedo Park Mklll there! Should be a '63?
    The rear wheelhouse cushion was the first thing I noticed, then the upholstery on the drivers seat, then the front bumper.
    That will be a lot of work, but I've done worse. I say I won't take on a rough project again, but I always seem to anyway. Besides, this is a Tux!
    It looks like all the floors and hat channels are the biggest items. My guess is there was carpet at one time? Much of the rest are flat panels. I asume you have a MIG welder?
    -Donny
     
    Aidan Turner likes this.
  7. Jun 25, 2020
    browncoat

    browncoat Member

    Maitland Australia
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    Sep 1, 2016
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    How is your welding skills Aiden? :lol:

    Looks a lot like mine actually.
    Half way through the repairs at the moment.

    I am using tread plate for the cargo area floor, and 16 gauge sheet to repair everything else.

    You will find a lot more to repair once you start looking closer and removing the bits you can see easily.

    I had the pleasure today of discovering a heap of body filler in the panels that I thought were nice and straight.
    The previous owner was an artist with the bog.

    [​IMG]

    [​IMG]
     
  8. Jun 25, 2020
    Dave Deyton

    Dave Deyton Member

    Fuquay-Varina, NC
    Joined:
    Oct 12, 2003
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    894
    Seems like the usual rust we all see in those places where dirt and moisture sit.
    Clean it well, remove the old filler, measure carefully. I make the repair panel before cutting out the old one.
    Then I put the new repair panel (usually 18 ga. cold rolled steel) up against where it will sit and scribe around the new patch panel.
    I cut out the old inside the line I scribed and carefully cut to the line so the patch panel fits well for welding. Since I have ground the area to bare metal, I usually use Blue Machinist Layout ink so the scribed line will show up well.
    When the new panel fits well, weld small places and let it cool, moving around a lot or the metal will stretch from the heat and it becomes a mess to straighten. Too much heat and all of a sudden the metal is wavy and your back to square one. You want that discolored HAZ (Heat Affected Zone ) to be small and about the same all around the patch panel. This will assure you less filler. Too much grinding can heat up the metal and cause problems also.

    Taking you time is the most important thing.

    I have to make myself slow down and not weld too far. Do one patch at a time so you can feel like your making progress.

    Hate the rust under the tool box. Still trying to figure out how to fix that with out removing the tool box on the M38A1.
    Best to remove the spot welds and remove the tool box and put in a new floor, the replace the tool box. On replacing the tool box, its best to source an old one from someone on the forum, the replacement I got was not right.


    Good luck, just takes time.


    Dave
     
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  9. Jun 25, 2020
    Twin2

    Twin2 not him 2024 Sponsor 2023 Sponsor 2022 Sponsor

    Virginia Beach, VA
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  10. Jun 25, 2020
    durangotang

    durangotang Member 2022 Sponsor

    Not Western CO
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    From my recent experience, here is my advice: 100% pay someone to sandblast it. Having an honest assessment of exactly what you are working with will allow you to make a solid plan of attack. Finding new problems while fixing known problems will drive you crazy and then you will end up posting about your struggles on ECJ5 like me.

    Secondly, old Jeeps are cheap. Don't be afraid to find a junker with a good tub and swap it onto yours before selling the rest of it for parts. 95% of the time this is easier and more cost-effective.
     
    Keys5a, Dne007, Walt Couch and 4 others like this.
  11. Jun 25, 2020
    blalp!

    blalp! Member 2024 Sponsor 2023 Sponsor 2022 Sponsor

    Concord, NH
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    This is sound advice! After sand blasting, you will have a lot less good metal left than you think. Aside from the obvious areas, you may find the tops of your quarters where the wheelhouses attach are a problem area.

    I’m repairing mine, and by the time I’m done 75% of it won’t be original metal. It’s a lot of work, but rewarding if you can see it through. My next project will likely get an aftermarket tub to save time.
     
    iharding likes this.
  12. Jun 25, 2020
    Aidan Turner

    Aidan Turner New Member

    Morristown, NJ
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    Yeah there was a carpet in the rear and rubber floor mats up front. I do have a MIG welder and I’m taking a welding class soon so I’ll be able to actually use it.
     
  13. Jun 25, 2020
    Aidan Turner

    Aidan Turner New Member

    Morristown, NJ
    Joined:
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    What do you think about making my own tool box?
     
  14. Jun 25, 2020
    Dave Deyton

    Dave Deyton Member

    Fuquay-Varina, NC
    Joined:
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    Making your own tool box is do-able, but requires metal working tools I don't have. Not to mention skills I don't have either.
    i took an old tool box missing parts to a metal meet and asked how to build another one and the steps and tools required were above my head.

    The repo tool box I have was thinner metal but could be made to work using the old tool box lid and some metal messaging to make it fit, I just sourced a new one.

    Dave
     
  15. Jun 25, 2020
    Howard Eisenhauer

    Howard Eisenhauer Administrator Staff Member

    Tantallon, Nova...
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  16. Jun 28, 2020
    fhoehle

    fhoehle Sponsor

    Harford Township, PA
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    By the time you replace the metal to get rid of the rust, there won't be anything left of the original tub. I would get a repop tub and not even think twice. My CJ6 was in the same shape, complete with plywood patches. I ordered an Aqualu body and have been so happy ever since. Both my son's Jeeps will get a MDJuan tub to start. Just my opinion, your mileage may vary.
     
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  17. Jul 22, 2020
    truckee4x4

    truckee4x4 Grant Kaye 2023 Sponsor 2022 Sponsor

    Truckee CA
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    Curious what everyone thinks is the best type of blasting to clean up a CJ5 tub and assess its condition for repairs? Soda? Media?

    I’m trying to find a shop in Reno to sublet this task to cause the wife doesn’t want any more (wet) play sand on the side of the house.
     
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  18. Jul 22, 2020
    Alan28

    Alan28 Well-Known Member 2022 Sponsor

    Châtillon en...
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    Well, it's a Jeep, rust... you like welding but days are only 24 hours. Maybe better/cheaper to get new tube or parts, just question of money. The idea is not only to train for welding, but also to drive a nice Jeep with friends or family in a beautiful sunshine day.
     
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  19. Jul 22, 2020
    Warloch

    Warloch Did you say Flattie??? Staff Member

    Falcon, CO
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    A good media blaster will take a look at it - assess the metal, types of 'stuff' on it, both thickness levels, curves in the metal and figure the best way forward for time and money. The good ones want to do it fast, but not so hard they blow through things or warp it from the heat. Water/Media blasting is real nice, but costly. Soda won't get 'all' of the stuff that can be on these old tubs.

    I just drop mine off and let the blaster I use decide - it was the best way to go on the '62/'63 build I'm doing now.
     
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  20. Jul 22, 2020
    Howard Eisenhauer

    Howard Eisenhauer Administrator Staff Member

    Tantallon, Nova...
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    See if you have someone local who does acid dipping.
     
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