I'm Patching the Rear of My Frame. With Pictures!!!!
My '94 Wrangler has holes in the frame around the PS rear shackle. I've looked around and didn't find a write up for the process so I will make my own. Here is an overview of the process I took. This will be ongoing so check back often.
-block the front tires and disconect the battery
-drain and remove fuel tank
-jack the Jeep up as high as you can get it. It's much more comfortable being able to sit under the Jeep.
-put jack stands under axle
-I put the stock jack between the spring and frame by the rear crossmember. Just snug it up to let the weight of the spring relax
-remove the shackle. You might have to play with the tension of the jack a bit to get the bolts out.
-pound the bolt sleave out of the upper bushing. Insert a punch big enough to not pass through the sleave
-then grab the bushing with pliers and work you way around pulling down and out
Now you can start cleaning up all the rust under the rear of the Jeep. This is a perfect time to clean up the frame, cross member, tub etc....While you have the tank down do as much as you can. I'm doing both sides while its down however only the PS side needs it.
I ended up removing my rear body mounts when i did mine. I have a 1" Bl too and glad I did. Makes it easier to get to the top of the rear frame. Also had almost all the body mounts loose too so the body could be lifted slightly. I also made my own patches for the both sides, tops, and bottoms. Made from 3/8 plate. My pieces go up the frame rails a bit til i hit good metal. I also fishmouthed the front of the plates to have more surface area to weld too. My rust was not as bad as yours but I had it on both sides.
Thanks for the input. I am worried if I try to take the body mounts off I'll break the bolts. I plan on plug welding the plates. I found a guy on Craigslist that has lazer-cut plates. Both sides $125 shipped. What do you mean by Fishmouthed?
I broke my rear bolt on the one side and a couple of others when i did my body lift so they came off easy for my frame repair. I also said 3/8 plate and lied, it was 3/16 plate. 3/8 would have been huge lol!
Fish mouth is basically what it sounds like. Instead of having a flat edge with lets say 4" of straight weld you get more suface area and stagger the weld when you fish mouth. I also plug welded them.
Here is a pic of my plates i made. Notice the open fish like mouth on one end.
I also made plates to follow the frame contour for the top and bottom. Welded it all together.
Here it is welded in. One on each side, did both pass and drivers.
Cleaned up and bedlined...
Strong like bull! sorry to hijack and I can remove my pics if you wish.
No that's awesome!!!! Keep the pictures. Good ideas. How did you get the body bolts off when they broke
Here is what I did to mine. This is the right rear mount, after cutting open the cavity with a cutoff wheel. The rusty remnant of the snapped off bolt is also in the picture. I made a weld nut of sorts and put it back in, now I have to close up the scar. Keep up the good work and above all, be safe!
Sorry, I didn't use your templates. I found these on Craigslist. I think these things look great. Laser cut 3/16". This should make it really simple. $125 shipped. I ordered them Saturday and got them today. Not bad. I will post some pics of the install.
How about printing the templates and laying them over the actual. Let me know how they do. If I need to make adjustments to the templates I can. That way, if someone else uses them they will be correct.
Im going to have to repair mine too.(95Yj) But make sure to have a look at the frame section for the transmission skid plate. it loves to rust there as well. were you able to repair the rear body mounts?
I will print those temps out and check them. I checked the skid plate are and it seems to be in good shape. It was only on the right rear. I think the exhaust had something to do with it because the frame, shackle, body, and gas tank skid plate were all rotten in that area.
Here it is. I already welded the inside and bottom. This is the outside. Be sure to use alot of clamps to keep the edges flat to the frame. I also plug welded the side plates. This kit was worth the money.
I found him on Ebay. 0llllll0 That is his member name. I just looked. He is asking $90 for the kit. The only thing I changed in the kit is I drilled 1/2" holes for plug welds. Let me know how it works out!!!!
im glad someone is doing a write up on this i have to do both sides on mine by the end of sept i hope to get the kit if i can find them on ebay. i found a guy on craigslist who makes them to... maybe the same guy??