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Old 04-22-2014, 10:41 PM   #1
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How bad is this rust

Read too many horror stories about rust on tj frames and things breaking/falling off. I cleaned out the whole inside of the frame and sprayed eastwood internal coating and I'm working to the outside. I took the skid plate off and only 1 out of 6 nutsert broke. I banged on the frame where the skid plate meets with a hammer and couldn't get any cracks or dents. But here is some pics of the worst spots near the rear.

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Old 04-23-2014, 06:19 AM   #2
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Seen worse: I would start wire wheeling and grinding the surface rust off right away. Use some naval jelly if you want a chemical solution. Get it down to bare metal and see what you have left. Doesn't look *too* bad...what happens when you poke it with a screwdriver? Probably worse on the inside. If it was stopped in there, and you cant poke any holes or using a hammer causes no fractures, then grind off the surface and paint. From the pics, you should be able to save it. Otherwise...Safe-T caps or replace sections. Good luck!

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Old 04-23-2014, 08:29 AM   #3
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That looks the same as my 97. It is mostly surface rust. you can check it for strength with a hammer, then clean it thouroughly and then paint it. I recommend POR-15. little more expensive, but is perfect for rust.
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Old 04-23-2014, 03:36 PM   #4
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I agree with the others, that doesn't look too bad. POR-15 is what I used, and it is great, but pricey. What are you going to do about the belly pan insert?
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Old 04-23-2014, 04:18 PM   #5
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Same with mine...didn't use POR-15 but I would put several coats of paint on. I'm not sure how durable POR-15 is or if it can be top coated on but I recommend rustoleum spray can bed liner to top coat if you can...durable and great stuff.
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Old 04-25-2014, 02:00 PM   #6
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Since I still have 2 boots holding the plate in, I'll hold of until I can buy another nutsert. I've never replaced them but hear it's simple. Just grind old one off and put new one in and tack weld it.
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Old 04-25-2014, 03:31 PM   #7
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Good luck. I had 4 of the 6 inserts go on me. I ended up cutting it all out (the whole bottom of the frame along the inserts), treating the inside of the frame, and then making two 30" long custom frame caps out of 3/8th steel (3" high) with welded in nut inserts. For the nut inserts, I welded in wheel lugs from German cars for the nut, and I use Japanese lug bolts to hold the pan in place. The frame caps were then welded into place. It worked great.

Here it is after being welded in, but before paint.


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