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Old 08-03-2010, 10:17 AM   #1
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To Bondo, Or Not To Bondo

Hi,

My TJ is having some serious issues with rust. The driver's side and passenger's side side panels are getting some pretty big holes in them, right around where the side panel meets the floor panel. Also the driver's side floor panel is starting to look kinda rough. However I am a little hesitant about buying sheet metal and paint and doing a patch job because I am no welder, and am afraid the final product will just look shoddy. When I say I am no welder I mean I have done it before, and due to a not so steady hand was awful at it. So I thought, why not try Bondo? It's not a permanent fix at all, I realize that, but if it will last through the winter then that's good enough for me, until I find time to practice welding some more. I would just buy the side panels, floor panel, etc, but to me that's a higher risk of screwing up, and then I would be SOL and stuck with giant, useless pieces of sheet metal.

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Old 08-03-2010, 10:21 AM   #2
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Check junk yards for body panels replace and paint .. or just replace and go rat

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Old 08-03-2010, 10:37 AM   #3
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Replace and paint with black primer!
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Old 08-03-2010, 10:43 AM   #4
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are you guys saying I don't need to weld to replace the panels? I thought the tub including the side panels was all welded together.
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Old 08-03-2010, 10:50 AM   #5
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Oh, your gonna have to weld ... but it would be cheaper finding body parts that might be in good condition in the junk yard instead of buying brand new replacement parts
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Old 08-03-2010, 10:59 AM   #6
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I'd just weld it, but that's me personally. My DJ has several very ugly welds, and one of the suspension welds is the very first one I ever did with a wire feed Whacked the **** out of it with a hand sledge to be sure it would hold, and no worries. It's dog ugly, but it's mine

You can bead both sides and then take an angle grinder to the "show" side... I've had pretty decent luck doing that.

Just remember that sheet metal goes FAST... biggest worry is putting a hole in it, but even "bad" welds in sheet metal get a pretty good grip from what I've seen.

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