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Old 04-08-2012, 09:44 PM
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Join Date: Nov 2011
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frame replacement

I am starting a project to replace the frame and tub on my YJ due to rust from Minnesota. I have acquired a salvage vehicle with frame, tub and a lot of incidentals. However, there are quite a few things that I will need to replace as I do the final switch over to the new frame/tub. I will be painting the frame and doing a paint job on the overall vehicle.

I am planning on timing the actual switch over to June when my Grandson will be out of school and be able to come from Texas to New Mexico to work with me to do the switch over. Due to that, I will be trying to get everything I can done ahead, like get the tub body work done and painted, etc. That way we can spend 2 weeks doing just the change over. I anticipate putting in a Rough Country 4" lift with 2.5" springs and a 1" body lift with all new mounts.

In order to prepare and not get stopped by not having something I really have to have and it isn't immediately available, I am making a list of all of the incidental parts that I anticipate I will need. I am looking for any help on compiling that list so I can prepurchase the items that wouldn't be available locally.

So far I have identified:
RC suspension
Frame mounted spring bushings
transmission mount and torque bolt,
U-Joints Drive shafts and axle
fluids (ATF, Diff, PS, Antifreeze, brake)
O2 sensor
Radiator, hoses, T-stat
wiring tubing (multiple sizes)

I would appreciate anyone, especially those that have done it, to jump in with any other items.

Also, any suggestions on frame and body paint/prep would be appreciated. The frame and body are very pristine as far as rust goes. A very little surface on a few spots on the frame. Living in NM I am not planning on going to the extreme that I would in Minnesota. Will just prep, prime and paint the frame with Rustroleum. Body painting above and below is not really for rust protection but more for appearance and durability. Frame and tub are from a 95 so they have good rust protection.

Also looking for suggestions on final exterior paint regarding both color and material. The existing Jeep is black with wide red stripe below doors and on hood. Replacement tub is black but will have full primer due to body work necessary. Windshield frame and fenders will be from original vehicle.

Thanks for any input.
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Old 04-08-2012, 10:09 PM   #2
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I just started the exact same project. Frame i originally had was extremely soft and rotted. I purchased a used one from Missouri. I took an angle grinder to the tough spots and wire wheeled the rest. I will be prepping with a product called marine clean and then doing 3 coats of POR-15. Their website is helpful with steps and products POR15, Inc. - Stop Rust Permanently - Repair Gas & Fuel Tanks. I have never used the product personally but I have seen short term and long term results and was very impressed. My Dad swears by Rustoleum. I used a high degree Rustoleum paint on the exhaust for my mustang. Driven in the rain and some salt. So far rust free going on 3 years. Not bad for 6 bucks a can. I'd suggest a youtube search for some of the reviews and steps others have taken. I would also look into a complete hardware kit from daystar or something to that caliber. A lot of people over look the cost of hardware and fluids. Not to mention odd ball tools some of these jeeps require. I will be sure to stay in contact as I will be doing the exact same process as you and your grandson. My suggestion. Get that frame finished and tub some what prepped. Get the new suspension on with some spare tires so then you can roll it around. Get the motor and trans swapped. Then go to work mounting the tub and doing the wiring. Don't forget the stainless brake and fuel lines. Best of luck !

87 yj, 4.0, small lift, 33s, slowly taking jeep-roids
75 cj5 304, Fiberglassed, 4:56, lifted, 35s
79 cj5 built 401
73 cj5 plow jeep.
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