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Old 03-05-2010, 01:07 PM   #1
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Question 90 YJ where to begin?

I bought a 5 speed '90 YJ last summer. Guy was restoring, kept good records and all paperwork. I know nothing about restoration, but it's getting me around so I want to fix it up. The floor is rotted all around and seatbelt mounts are rusted out. Should I get the stamped floor kit or just panels to start?

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Old 03-05-2010, 10:01 PM   #2
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I was told my frame is also shit

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Old 03-05-2010, 10:19 PM   #3
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Sorry to hear that.
you can buy everything from a whole new frame and body or if you have the mechanical ability you can fix almost the worse case of rot.

or sell or part out and take the money and buy again with your new found knowledge of what to look for.
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Old 03-06-2010, 07:15 AM   #4
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Im doing the restore myself. If you are not deep into this money wise and not looking for a long project I suggest selling or parting out and getting a driver. I thought I would get a frame/tub, swap my drivetrain, and be golden.....that was about 5k ago and Im still working on it. I enjoy the project and its not my daily so I can go at a slow pace work and spending wise.

I will tell you with a large amount of rust there is going to come alot of broken bolts, siezed bolts, scuffed knuckles, and metal cutting.

again if you enjoy the challenge and have some time and money to spend get a rolling chassis and have fun with it. you will definitely have a true understanding about what you are driving.
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Old 03-06-2010, 06:15 PM   #5
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I was thinking the same thing (frame/tub) but it's not realistic as it is my daily. Plus PO was not as meticulous w/ his work as his records. Seems to me, he was going ass backward...chrome grill, hinges...lipstick on a pig. Parting out may be my best bet. I don't have the skill level or the tools to do by myself. Impulse control would have been nice, but hadn't had a jeep in a long time, so I smooched that porker before I could think clearly.
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Old 03-06-2010, 07:44 PM   #6
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weld in floors panels
weld cross and box frame
drive it ,drive it

screw new tub and frame
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Old 03-07-2010, 08:47 PM   #7
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Found someone willing to bust his butt on it w/ me; used to build them from the ground up. And he's down for the whole project, $500 at a time. Tomorrow marks the beginning of the rust removal stage. Here's to uncovering the next layer of problems...wish me luck
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Old 03-08-2010, 07:17 PM   #8
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keep us posted!
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Old 03-08-2010, 07:24 PM   #9
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take some pics and post them
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Old 03-08-2010, 07:30 PM   #10
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Only in the wild world of Jeep do we consider tubs and frames "replaceable parts"
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Old 03-08-2010, 07:34 PM   #11
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Only in the wild world of Jeep do we consider tubs and frames "replaceable parts"
hahahahahahahaha soo true!
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Old 03-08-2010, 07:41 PM   #12
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Resurrect that puppy and then show it off! It may not seem logical but it will be fun. I have been having fun getting my 97 up to par myself. Im learning so someday when I have more time I can bite of a project like this! Good luck man!
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Old 03-13-2010, 06:50 PM   #13
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There is a company out there that makes frame sections for Jeeps. That way you can fix the part of the frame that is rotten.
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Old 03-13-2010, 06:51 PM   #14
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Be careful of some of the floor panels out there for sale. They are thin and aren't worth the price.
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Old 04-11-2010, 08:10 PM   #15
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Update: Decided not to go w/ the floor panels ...some thick sheet metal instead. Seats and belts are in. Got talked into doing some cosmetics, so dents are all banged out, rot on doors cut out and filled. After pulling off running boards, found a bunch more (of course). Now that's done, so everything is put back together. Welded some of the frame but it really needs to be replaced...a band-aid for now. So far, running total is 2500. Not bad for a ride worth 1800...Jeepsus Chrystler, I must be sick! I'll get some pics up soon.
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Old 04-11-2010, 08:13 PM   #16
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@duaneduanet, Do you know the name of that company? I've gotta check that out.
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Old 04-13-2010, 05:30 PM   #17
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Half ass paint job and some hardware to put back on. Next step is the suspension.
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Old 04-13-2010, 05:41 PM   #18
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PICTURES! Geez, ya got a camera on your phone.

And this is a funny line:
Quote:
Impulse control would have been nice, but hadn't had a jeep in a long time, so I smooched that porker before I could think clearly.
We've all been there, in one way or another.
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Old 04-13-2010, 06:01 PM   #19
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[QUOTE=Geoff@Bestop;597589]PICTURES! Geez, ya got a camera on your phone.

I finally got a few pictures. My profile picture is from today. I can't find my 'before' pics...and I've been trying to upload the rest but don't know how!
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Old 07-16-2010, 12:32 PM   #20
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Update on YJ project

The body and floors have been resurrected. Power steering pressure hose went almost immediately after. I replaced that with the aid of forum posts (Thank you all!) and a random dude who happened to be watching me struggle w/ cutting off a stripped bolt. Being a woman does not help when brute force is called for...neither does having the wrong tools.

Good news is frame is actually sound, whacked a screwdriver into every square inch...just surface rust. I'm in the process of wire brushing that crap out a little at a time.

Next, I have to decide between replacing the head and doing an engine swap. Any opinions? And, no, I won't be tackling this alone!
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Old 07-16-2010, 01:37 PM   #21
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The body and floors have been resurrected. Power steering pressure hose went almost immediately after. I replaced that with the aid of forum posts (Thank you all!) and a random dude who happened to be watching me struggle w/ cutting off a stripped bolt. Being a woman does not help when brute force is called for...neither does having the wrong tools.

Good news is frame is actually sound, whacked a screwdriver into every square inch...just surface rust. I'm in the process of wire brushing that crap out a little at a time.

Next, I have to decide between replacing the head and doing an engine swap. Any opinions? And, no, I won't be tackling this alone!
The question is how is the rest of the engine? Are your rod bearings shot? How's the cylinder walls? Instead of buying a replacement engine you could just rebuild the one you have if you're gonna sink the money into a head.
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Old 07-24-2010, 12:15 PM   #22
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Well, apparently, there's an oil leak coming from somewhere behind the engine. I've read that this might be the rear main seal? I'm not a mechanic and I don't know how to check the rod bearings or the cylinder walls. Any tips? I replaced the pcv valve and got a new oil filler cap, hoping it was something simple. It wasn't.
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Old 10-01-2010, 12:07 PM   #23
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How did your sheet metal floor install work out? What thickness did you use? I got a new project 91 YJ with a completely rotted out driver side floor (it's literally all gone). I picked up some 1/16'' sheet metal and was just going to grind/cut out all the rust, hammer it to shape and pop rivet it in. Its not the most elegant or structural solution, but its cheap and is better than the 1x1 piece of plywood the past owner had.
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Old 10-01-2010, 02:20 PM   #24
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It worked out perfectly...of course it still has shrapnel from the old floor dangling in places, but not a big deal to cut it away cleanly. Used some soundproofing, looks nice, but haven't rhino lined yet. I don't remember what thickness the sheet metal was, but 1/16" sounds about right. Unfortunately, after the install, the original seat belt roller on driver's side seized, so the guy who was 'helping' me welded the anchor to the floor (BOO). Now I have to cut out that portion and bolt in a new one. Still a loooong way to go! How's your project looking?
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Old 10-02-2010, 12:17 AM   #25
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Originally Posted by massyj View Post
I bought a 5 speed '90 YJ last summer. Guy was restoring, kept good records and all paperwork. I know nothing about restoration, but it's getting me around so I want to fix it up. The floor is rotted all around and seatbelt mounts are rusted out. Should I get the stamped floor kit or just panels to start?
I HATE rust ... it never ends...

My opinion...either enjoy it the way is until the day it breaks into pieces. I've had a Jeep like that and had the best time in it...never had to worry about it.

Option 2: Part it out and find a rust free Jeep...make a trip out of it and visit the south. If you need help send me a PM. I'd rather start with a good platform even if it doesnt run.

I like option 1 and then option 2 ... have fun and enjoy what you have.
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Old 10-06-2010, 07:55 PM   #26
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Glad its coming along man. I was in your shoes about a year ago when i first got my yj. Its all worth it in the end. Good luck bro.
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Old 10-09-2010, 12:13 PM   #27
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Glad its coming along man. I was in your shoes about a year ago when i first got my yj. Its all worth it in the end. Good luck bro.
Thanks. It's always something, right? I plan to keep putting my all into it until she gives up completely...and I don't foresee that happening. We're equally stubborn. Did you do your own work? I'm learning about each part as it breaks, so I have to buy tools and research problems one at a time.
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Old 10-09-2010, 03:41 PM   #28
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I try to do what i can. But like if its somerhing "big" mechanical wise i dnt really mess with it. But it sure is a big learning experience thats for sure.
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Old 10-26-2010, 02:41 PM   #29
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It worked out perfectly...of course it still has shrapnel from the old floor dangling in places, but not a big deal to cut it away cleanly. Used some soundproofing, looks nice, but haven't rhino lined yet. I don't remember what thickness the sheet metal was, but 1/16" sounds about right. Unfortunately, after the install, the original seat belt roller on driver's side seized, so the guy who was 'helping' me welded the anchor to the floor (BOO). Now I have to cut out that portion and bolt in a new one. Still a loooong way to go! How's your project looking?
Project is coming great! got a floor in, i'll have pics soon. Moving the seat back, then the gas tank can go back in. Still troubleshooting the fuel gauge and power steering but i should be on the road (and off) in no time!
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Old 10-26-2010, 02:44 PM   #30
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Thanks. It's always something, right? I plan to keep putting my all into it until she gives up completely...and I don't foresee that happening. We're equally stubborn. Did you do your own work? I'm learning about each part as it breaks, so I have to buy tools and research problems one at a time.
You mentioned buying tools as you needed....

I sucked it up and bought a 255 craftsman automotive set. best $200 i ever spent. no more borrow sockets from people, working on the jeep and needed a wrench you don't have, or worse yet, trying to use one you shouldn't and tearing up those F@$^%# TORX! As a new-to-the-game jeep owner, I could already tell you, buy the tools, then do the work. not the other way around.

best of luck!

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