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Old 01-28-2014, 10:55 PM   #1
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The 1 car garage Resto

Sold my 5.0
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Old 01-28-2014, 10:56 PM   #2
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to buy my 89 Wrangler
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Old 01-28-2014, 10:58 PM   #3
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The first thing, (besides the rot on the underbelly), was pointed out to me when I sent this photo to a good buddy. He told me to look at my rear wheel. Hmm...
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Old 01-28-2014, 11:03 PM   #4
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The rear leafs were taken off of a CJ and mounted backwards by the PO! The 4wd did not work because the transfer case was wasted. Look at the slack in that chain! It was wearing into the interior shell! Before taking apart the Tcase, I installed the Positive engagement kit to the front axel. That did not resolve the 4wd issue, but no loss on that upgrade.
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Old 01-28-2014, 11:04 PM   #5
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Okay, so I got a Tcase from an overpriced junkyard, threw it in, went out to test the 4wd.
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Old 01-28-2014, 11:05 PM   #6
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After testing the 4wd, I realized I needed a "trail buddy".
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Old 01-28-2014, 11:06 PM   #7
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So, ran her for a while like that, enjoying the summer. The rot on the tub was the next area of concern. The roll bar mounts were pushing through the floor, driver side floor pan just gone, seat belt mounts gone, etc. So I came across this through a buddy.
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Old 01-28-2014, 11:10 PM   #8
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The new tub however, did not come ready for installation. It was, in fact, in a little worse shape than I anticipated
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Old 01-28-2014, 11:11 PM   #9
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So, I got me one of these. And I got me one of those. That is a restoration job I did on that press. My neighbor's daughter gave it to me. I didn't need the press for the body work, but will be using it very soon for some frame work.
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Old 01-28-2014, 11:14 PM   #10
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And I went to work on the rot. These were the two bad areas, the driver side floor pan and rocker panel, and the rear wheel well pass side.
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Old 01-28-2014, 11:17 PM   #11
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Some of the floor/rocker repair. I made a major boo boo when I cut loose the old rocker panel. The tub dropped, twisted, and tweaked about an inch in each direction when I made the last cut. A little foresight would have come in handy there. I also cut the jamb into the radius on the tub because that's where the new panel ended. I should have cut back the new panel, where the radius was done with, then I would have been working on a straight line. Hopefully somebody learns from my mistakes.
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Old 01-28-2014, 11:17 PM   #12
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Man, I went super-slow with merely tack-welds, spaced out, AND immediately cooled them with a blow gun and that damn thing still warped on me! Ah well, i'll just blame it on the trees.
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Old 01-28-2014, 11:22 PM   #13
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On to the mess in the back. Made great use of some trash I spotted at the curb on this one.
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Old 01-28-2014, 11:25 PM   #14
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shot of the inside. Not too worried about it not being corrugated like the rest of the bed. Seat going over top, it's a jeep, who cares.
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Old 01-28-2014, 11:29 PM   #15
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The first few pics are replacing the front driver side body mount. The second set is the body mount hidden under a brace that connects with the floorpan and the support beam running from side to side was a body mount which was destroyed. This is how I fabbed one up. Probably could have gone about it in an easier method, but didn't mind the work.
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Old 01-28-2014, 11:33 PM   #16
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the rest...
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Old 01-28-2014, 11:39 PM   #17
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Had to weld a couple nuts in place for seat mounts. Rethreaded ones that were still in tact.
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Old 01-28-2014, 11:42 PM   #18
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First shot is of it all cleaned up with Marine Clean. Second shot is the Metal Ready zinc phosphate in action. You can see this stuff work.
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Old 01-28-2014, 11:43 PM   #19
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Aw yeah! That's what I'm talking about. POR 15. Wicked stuff.
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Old 01-28-2014, 11:45 PM   #20
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Wrapped up the tub behind the garage and took a break for the holidays. Most of all the annual hot tub party.
After things were put back in order I started dismantling.
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Old 01-28-2014, 11:47 PM   #21
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A good buddy stopped by and helped me get to this point. We left what we could attached to the interior of the firewall, such as the pedals and ductwork. That way I can pull it as I need it and will know where it goes. I'll probably torch off the firewall so I can keep it around without the yard looking like a junkyard.
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Old 01-28-2014, 11:48 PM   #22
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This is where I left it today. Got some rot to repair in the rear. I cut off that flimsy bumper support to access the rot. I'll replace it with that heavy piece of channel I stole from work. Be nice for a hitch support. The front 3/4 of the frame is actually pretty nice. I got Eastwood Internal Coating on order and some more POR 15 along with the Chasis Coat coming also. I'm planning to hit the junkyard for TBI parts for a fuel injection conversion, thanks to info BernieBikes passed on to me.

I put this up in case it may be of any use to others, and to welcome any comments or suggestions that may push me further toward success. Thanks!
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Old 01-28-2014, 11:53 PM   #23
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Back at it today. After trying to work around it, I decided to get that dang axel out of my way. Was extra work, but will make working on the frame a lot more comfortable. Also took out the exhaust. No biggie.
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Old 01-28-2014, 11:54 PM   #24
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Some goodies showed up during lunch.
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Old 01-28-2014, 11:55 PM   #25
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The hole in that crossmember looks like an easy place to get warmed up.
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Old 01-28-2014, 11:56 PM   #26
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Took about 20 min of heat, but I got that sucker to bend.
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Old 01-28-2014, 11:58 PM   #27
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Had to quit before I was able to trim it down, but very happy with the weld quality. Landed it on the right setting this time!
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Old 01-29-2014, 12:00 AM   #28
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Well, back at it again. First course of action was to clean up that patch from yesterday.
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Old 01-29-2014, 12:03 AM   #29
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So, once again, the very rear of the frame is the sole area of frame repair for me. The problem is that I am working around two body mounts and 2 leaf spring mounts, so I am very concerned with losing any of those locations. I certainly do not want to chop off the frame and try to replicate it freehand. I need to replace the outside and inside panels along with the bottom edge on both the passenger and driver sides, all while not disturbing the body and leaf mounts. I decided to cut out and replace the rot section by section. I spent some time making cardboard templates before cutting anything out.
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Old 01-29-2014, 12:04 AM   #30
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Once I had a template, I made the replacement piece. Once I had the replacement piece, I marked it out onto the frame and then I cut it out of the frame.
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