I fixed my pillar rust with part of an old jack last night. I still need to sand off most of the body filler, prime and paint. But heres a few pics of the steps along the way.
I went to pull on my pillar and it bent w/my window down. Ok, enough is enough, time to go into ICU for emergency surgery!
Here is a pic of the metal all rusted out, most of you w/older YJ's have probably seen this before lol.
I cut a bunch of the old rusted steel out and removed the paint anywhere I wanted to weld
This is the part from an old Jack, it worked perfect. I was able to cut it, flatten it and weld it in.
Grinding off some more paint to get a good clean steel surface to attach to
mock up, before finishing the trimming and flattening.
I used a big vice and a body hammer to flatten the edges and also those little spots where the jack piece was dimpled
drilling holes to spot weld on the inside edge along the window
drilled and cleaned off the paint to weld
welding everything together
all welded in, also folded the tabs we cut into it over the backside of the frame to help stablize it
grinding down the welds
all cleaned up and ready for a little body filler to smooth the edges
looks like a lot of bondo, which it is
but about 90% of it will be sanded off. I'm letting it sit for a day or so, then I will sand it smooth, prime and paint white again.