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Old 03-01-2013, 03:26 PM   #1
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Hey guys. I'm looking for advice on repairing rusted fenders on a 2000 tj. My girl doesn't want to buy new replacement fenders and tube fenders don't offer the coverage needed. The only option I have is bondo or filler. I don't have access to a welder. If anyone has opinions on products to use our steps to take I'd appreciate the help. We live in Pennsylvania so rust is common. Trying to patch it on the cheap and keep it looking decent. Here is a pic of her Tj.

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Old 03-02-2013, 12:14 PM   #2
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I was faced with a similar situation, looked at a bunch of different options... Any amount of body fill or fiberglass you put in there is not going to stay long unless you cut out the old rust and replace with new metal. I considered heading down to the local metal shop and picking up some 18-22 Guage checker plate aluminum and capping the fenders, it would cover up the rust and buy you some time ( but totally depends on how much fender you have left to work with...) the option I chose was purchasing 2 new ones... Our auto salvage spot sells them for 140 a side... Can't go wrong! Good luck bud!

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Old 03-02-2013, 01:21 PM   #3
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It looks like a nice Jeep. Why not fix it right? Body filler is not the answer, if you don't have the means to do metal work why don't you look for some used fenders. I see them on CL for $50-$100 each occasionally.
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Old 03-02-2013, 01:35 PM   #4
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My front steel fenders (on the top) are rusting thru, so I'm biting the bullet and paying a pro to fix both, which he will remove all the rust and re-weld a plate on top, then prime and paint/clear coat and undercoat the fenders with rockguard to prevent this from happening again. He did a quarter panel for a previous truck about 2 years ago and did an awesome job. Cost for my TJ will be about 400$.
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Old 03-02-2013, 01:40 PM   #5
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What part of PA? I used to work at R&W truck service in Starbrick. Just wondering why are you concerned about the coverage of a tube fender?
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Old 03-03-2013, 05:33 PM   #6
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Thanks for the tips guys. My opinion is to buy new fenders or find decent used. My girl wants the patch job because it's cheap. It is her Jeep. The rust is eating through the fenders in spots. I live in the poconos and have heard that we can run into problems without proper tire coverage so we turned away from tube fenders. Unless you guys know of stock or close to fender width. I wasn't able to find any. Maybe your posts will help my argument that new fenders are the way to go.
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Old 03-03-2013, 07:43 PM   #7
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For me to buy new steel fenders, I'm looking at 800$+shipping+taxes+the paint job(buying the parts inside Ontario, Canada). If it were super bad, then I would be inclined to replace but they arent that bad and my body man has done previous work on an older truck I used to own so I'm not worried.

Here, check out what my option for new is:

Just Jeeps :: Body - Fenders Stock Replacement :: CC...

Just Jeeps :: Body - Fenders Stock Replacement :: CC...

left and right fenders...
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Old 03-03-2013, 08:17 PM   #8
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Ok. Not bad. I did find fenders new for $180 a piece. She still wants the patch job. So i guess I'll be getting some metal filler and rust prevention. Thanks for the info guys but she isn't going for the new ones. Maybe when the filler doesn't hold up she will see our argument.
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Old 03-03-2013, 08:21 PM   #9
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I just bought a new fender and Bedlined them so I didn't have to paint match the new one. Cost me about 100 bucks and a couple hours of work(after bedlinig)
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Old 03-03-2013, 08:54 PM   #10
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I am repairing my rust on fender this week. Lot of work, I will most certainly post up pictures of my fix. So far what I did was, cut all the rust out and bent 22G steel. Will weld in and bondo, primer ,paint. Will post up pictures when job complete.
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Old 03-03-2013, 10:16 PM   #11
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If I had all the proper tools, I'd do the work myself... Tho have done previous work on my last vehicles that had minor rust situations going, my friends couldnt even tell the difference until I pointed out the flaws. What I wouldnt give for a garage, mig welder and lots of steel lol
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Old 03-04-2013, 12:35 PM   #12
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Old 03-04-2013, 01:01 PM   #13
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If the fenders have LARGE holes, you could use some screen door mesh for a form/grabber for the bondo. Just make sure to clean it well before putting it on AFTER you wire wheel/brush the heck out of all the rust and shoot it (fender) with primer first. You could use JB WELD to attach the screen to the underside, then fill both sides and finish to your liking. This is what will be happening to my fenders this spring. You could also do like a POR 15 system on the rust areas first also. Just some thoughts.
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Old 03-04-2013, 01:20 PM   #14
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Quote:
Originally Posted by jksport12 View Post
I live in the poconos and have heard that we can run into problems without proper tire coverage so we turned away from tube fenders. Unless you guys know of stock or close to fender width. I wasn't able to find any.
Smitty built XRC series are what I'm thinking about getting the previous owner must've left battery acid or something on the top of the passenger side fender so I'm gonna buy new ones after I earn some cash from some extra jobs this summer. They are only slightly narrower than the regular fenders. I hope you have good luck with the patch job though.
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Old 03-04-2013, 02:37 PM   #15
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Ok. Not bad. I did find fenders new for $180 a piece. She still wants the patch job. So i guess I'll be getting some metal filler and rust prevention. Thanks for the info guys but she isn't going for the new ones. Maybe when the filler doesn't hold up she will see our argument.
Sounds like your kind of caught in the middle.. You should tell her your not going to waste your time on something you know wont work. By the time you buy filler, primer, paint, sand paper and some sort of mesh backing your almost to the cost of one replacement fender. Not to mention your time, you will spend many hours on it and in the end it will look like crap. I'm not trying to give you a hard time, just trying to save you some grief.
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Old 03-04-2013, 04:17 PM   #16
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I see your in the pa area. There is a giant junkyard off 80 or 81 up by where it splits for Scranton and Binghamton. They have a whole section of jeeps. Sure you can get the fenders cheep. They will even pull them for you but it is cheaper to do yourself. I believe it is Gary's or Harry's u pull it. I lived in Milford for a while and got many parts there. They even have a bus on the yard that will drive you down to the proper section. When I went they let you carry 1 small toolbox on the yard with you. If you can find the # I'm sure they will give you a price for what you need.
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Old 03-04-2013, 04:40 PM   #17
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Thanks again for the tips guys. I'll call harry's u-Pull it. Knowing my girl, she will probably still want the patch job. I'll let you guys know what she decides and I'll post pics of the carnage.
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Old 03-04-2013, 05:52 PM   #18
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Harry's U Pull it is a great place! It is near Hazleton, Pa I live in Wilkes -Barre and it's close by. I have been trying to get there myself for some stuff.
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Old 03-05-2013, 08:35 AM   #19
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Would of loved to ordered that BUT it says the seller only ships to the US of A.
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Old 03-05-2013, 09:16 AM   #20
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Same problem with my 97 fenders. Theres a brace right under where they tend to rust out that catches and retains muck and water. What ever you end up doing make sure you clean and coat that area really well to prevent rust in the future. I got lucky and found a guy putting tube fenders on his TJ and he sold me his rust free ones, $200 for the pair. The local powdercoaters are going to blast and coat them (color matched) for another $200, so I shouldn't have the problem again.
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Old 03-05-2013, 09:19 AM   #21
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Harry's U Pull it is a great place! It is near Hazleton, Pa I live in Wilkes -Barre and it's close by. I have been trying to get there myself for some stuff.
Never been there but I've heard great things, it's just that it's a three hour drive one way for me..
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Old 05-31-2013, 11:22 AM   #22
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I had the same issue with my fender, and I decided to do a little patch work. The PO had a black diamond plate covering up the rust, so I removed the plate and found the rust. I knew the rust was there when I bought it. What I did was cut out all the rust and sanded it away, then put a piece of metal and welded it in place of the hole, used bondo to try and get it as smooth as I can, then primer, and painted it.
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