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Old 04-29-2013, 03:50 PM   #1
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Roll Bar Removal.

As I was going through my 2002 to make sure I address any and all rust before I put her on the road, I noticed a couple spots by the rear passenger's side roll bar mount. I knew I was going to have to remove the roll bar in order to get at the sheet metal. 20 torx bolt removals later... what an ordeal.



AND, this thing is pretty heavy. I should have had someone to help get it out, but, luckily no one was hurt.



I found another small rust spot under the front passenger's mount as well. I will post how it comes out.



Next stop is to clean up, and weld fresh sheet metal, fill, prime, and paint.



I threw the soft top back on without the roll bar, to keep everything dry, while I work on her.




-Jim
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Old 04-29-2013, 04:05 PM   #2
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Looking Good. I have a question: What Armrest is on the Center Console Lid?

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Old 04-29-2013, 05:27 PM   #3
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Looking Good. I have a question: What Armrest is on the Center Console Lid?
The armrest is a custom piece I made. When I bought the Jeep, the plastic lid was cracked, and it would pinch my arm. I made the armrest out of a metal plate that had 4 bolts welded to it that went through the lid, and into another plate, then fastened with nuts. I padded it with old towels, and furniture padding, then riveted it to the metal plate.

It's very sturdy, and makes a comfortable spot to rest you arm now.
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Old 04-29-2013, 05:31 PM   #4
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I was thinking... why would you leave the bars above your doors on??? Great time to drop the front window...but since your putting the top on I get it now.

I am 5'9" 155 lbs and I took the cage out by myself easily.





I just had better tools.

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Old 04-29-2013, 06:03 PM   #5
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Did you get that kind of rust from living so close to the coast? I'm just tossing out a guess. My TJ's only 2 years younger than yours, but I want to make sure I stop (or at least slow down) rust for as long as I can.
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Old 04-29-2013, 08:13 PM   #6
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Jeffery, I'm not sure where the rust came from. I bought my wrangler last July, from a good friend, who bought it new. He NEVER washed it like it should be washed (undercarriage, and every nook and cranny) He just drove it year round... and a couple of time at the beach. I have spent the last 8 months going through the entire thing, and this was the last bit that needs repair. It's not bad at all. I think it's a poor design myself. The rubberized adhesive that they goop all around the base of the roll bar looks like it can trap moisture and then cause rust to start. If I were you, take a small screw driver, and poke through the rubber at the base of both of your front mounts spots (remove a small 1/2 inch piece) and look for any rust. If you see any, then it's probably under the entire roll bar base. Good luck.
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Old 04-29-2013, 11:41 PM   #7
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What did you use to remove the goop/rubber?
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Old 04-30-2013, 09:32 AM   #8
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What did you use to remove the goop/rubber?
I used a couple different sized, flat head screw drivers, and a small hammer to get under the seam sealer.



Funny thing is, before I bedlined the tub, I cleaned everything and it "looked" great... Little did I know, that there was rust hiding under the seam sealer, at the rollbar mounting plates.



For the most part it looks a lot worse than it is. I will be tackling the clean up and repair this weekend.

-Jim
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Old 05-01-2013, 01:53 PM   #9
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Quote:
Originally Posted by G-LOVE View Post

The armrest is a custom piece I made. When I bought the Jeep, the plastic lid was cracked, and it would pinch my arm. I made the armrest out of a metal plate that had 4 bolts welded to it that went through the lid, and into another plate, then fastened with nuts. I padded it with old towels, and furniture padding, then riveted it to the metal plate.

It's very sturdy, and makes a comfortable spot to rest you arm now.
Very cool. Thinking about making one now, thanks.

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