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Old 10-23-2013, 10:09 AM   #1
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YJ Drivers door pillar rust fixed with part of an old jack

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


cutting time...


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.

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1994 Wrangler YJ I6 4.0 H/O Auto 3 spd. 4" RC (33x12.5) (15x8) 3:54 Gears
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Old 10-23-2013, 08:22 PM   #2
Guesses a lot ;)

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Sweet fix guy! I have that same rust spot on mine kinda and I have some old jacks laying around...lol

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Old 10-24-2013, 08:39 AM   #3
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thanks! I'm impressed with how much strength I have in the door frame now. It was hopeless for quite awhile lol.
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-Chris
President, ThumbJeeps
CB Callsign "AirForce One"


1994 Wrangler YJ I6 4.0 H/O Auto 3 spd. 4" RC (33x12.5) (15x8) 3:54 Gears
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