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Old 03-30-2011, 08:50 PM
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body work on yj

So when i got my 92 yj it had some minor cosmetic issues and this spring is time to get em out. My problem is with the stamped 'JEEP' logo on the side by the door, some of the rot bled into the logo and i want to keep it. I was hoping that someone had the same problem and would be able to tell me how they fixed it, any help would be awesome, thanks.

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Old 03-30-2011, 09:03 PM   #2
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Old 03-30-2011, 09:46 PM   #3
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this is the one sorry
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Old 03-31-2011, 08:52 PM
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ok thanks im not sure yet if i should grind the spot out or if i should just replace the whole panel.
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Old 04-01-2011, 07:58 AM   #5
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My self I would replace it.

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Old 04-01-2011, 04:31 PM   #6
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If you just grind it down till the rust is gone if it's not all the way through then you need to put rust mort on it for about 24 hours than do the repairs that will keep the rust from coming back .and even if you cut it and weld a new piece I would still do it . You can get it at an autobody supply house it's worth it if you love your jeep like I love mine
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Old 04-01-2011, 05:05 PM   #7
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There is no better way than to cut out the rust and replace the cancerous section with new. Do it right, do it once.
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Old 04-01-2011, 06:35 PM   #8
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Listen if it's not through use the rust mort if it has a hole then cut it out and weld atleast that's how we do it in our families body shop the reason being the rust mort is a chemical that we've use for a couple of years that stops rust like if it had never happened. When you weld a piece in,cause if your cutting a piece the correct way is to weld it back, when you do the metal around the weld area is going to warp there is no way of going around that it's metal getting really hot and it's gonna warp so now you have to shape it nice and if that metal happens to warp and stretch good luck getting it straight I'm not trying to scare you just giving you worst case scenario so your prepared so either way you gotta do body work but it's more work if you weld and if your jeep needs it fine but just cause you have rust doesn't mean you have to cut it out. On my floor I recently had two repairs one was a hole so I cut it about 2inches bigger than the rust and welded it but the other was rust but not deep so we grinded till it was clean of rust put rust mort and did the body work the next day and done and I've been in the business since I was 18 and I turn 35 Wednesday and I had the means to do it welded but it wasn't necessary
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Old 04-01-2011, 07:28 PM   #9
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The impression I get from the OP using the term "rot" is that it is more than light rust. What you are talking about is surface rust and light pitting, which grinding out and using a rust converting/ preventing product is a suitable repair. The problem I have seen on many vehicles I have owned, is improper rust repair. They sand it out, cover it up, paint it, and go on their merry way, but within a few years, the "repair" is blistered, and the light pitting has turned in to a rotten body panel. No one said the best way was easy, but it can be done, even by those with little welding experience. If welded the right way, you won't cause significant warps... I just did my DS floor pan last weekend, no warpage. Knowledge before you start to work is the key.
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Rectangle headlights ARE kinda cool.
YJ does NOT stand for "Yuppie Jeep".
Jeeps should only have TWO doors.
You should ALWAYS wave at other JEEP drivers.
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Old 04-01-2011, 08:03 PM   #10
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Originally Posted by MellowYellow89YJ
The impression I get from the OP using the term "rot" is that it is more than light rust. What you are talking about is surface rust and light pitting, which grinding out and using a rust converting/ preventing product is a suitable repair. The problem I have seen on many vehicles I have owned, is improper rust repair. They sand it out, cover it up, paint it, and go on their merry way, but within a few years, the "repair" is blistered, and the light pitting has turned in to a rotten body panel. No one said the best way was easy, but it can be done, even by those with little welding experience. If welded the right way, you won't cause significant warps... I just did my DS floor pan last weekend, no warpage. Knowledge before you start to work is the key.
Well said brother!!!

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Old 04-01-2011, 10:05 PM   #11
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I m sorry but no matter how good of a welder you are, you weld any and I mean any body panel and there will be warping that's not my opinion that is fact.
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Old 04-01-2011, 10:05 PM   #12
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And it's obvious if you do incorrect anything it won't work
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Old 04-01-2011, 10:10 PM   #13
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Ps welding a body panel should not be done by someone with little welding experience that's just bad advice I'm all for people working and doing things for themselves but body work isn't mechanics
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Old 04-01-2011, 10:45 PM   #14
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Psss, the gentlemen also said he didnt know if he should grind the spot out or replace the panel that to me meant you could grind the spot out like he said that's why I mentioned what I did. Just saying
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Old 04-01-2011, 11:02 PM   #15
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I m sorry but no matter how good of a welder you are, you weld any and I mean any body panel and there will be warping that's not my opinion that is fact.
It will warp in the HAZ (heat affected zone) but not outside, the key is to keep the HAZ as small as possible with good penetration, and you will have no SIGNIFICANT warpage. It is done all the time. A series of small tack welds allowed to cool, heating expands, cooling contracts all in the HAZ.

I don't mean to argue, but welding body panels is nothing to be afraid of, and no one should be afraid to learn first, then try the PROPER way to do it. I am not saying they should just start out on body panels. I am a self trained welder, if I can do it without significant warpage, anyone can as I have no professional training. I do, however, have Quality Assurance degree and have a few hundred hours of training concerning welding processes, I know what is and is not possible where warpage is concerned. It is all about using the minimum amount of heat needed, and making allowance for cooling... The HAZ is where its at.


Ps... Its all good, we all have something to offer, it is up to the OP to make the final call.
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A few FACTS:
Rectangle headlights ARE kinda cool.
YJ does NOT stand for "Yuppie Jeep".
Jeeps should only have TWO doors.
You should ALWAYS wave at other JEEP drivers.
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Old 04-01-2011, 11:06 PM   #16
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I'm not arguing you seemed like you jumped all over me about what I said and if you read what I said first all I said was if it's not rotted all the way through
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Old 04-01-2011, 11:09 PM   #17
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The guy asked for opinions I gave mine and you jumped all over me that's all. Not saying your wrong but neither am I in any of what I said
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Old 04-01-2011, 11:10 PM   #18
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Again though I'm seriously not arguing I agree we all can learn something from each other we cool I hope.
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Old 04-01-2011, 11:16 PM   #19
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I didn't mean to sound like I was jumping on you.... I am an analytical person, and in text it can translate to my being an @$$ I guess. Again, its all good. We agree on minor rust repair vs. major rust / rot, we are both right.

Its a brotherhood thing. We always cool Bro... Its the Jeep in us all that binds us together.
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A few FACTS:
Rectangle headlights ARE kinda cool.
YJ does NOT stand for "Yuppie Jeep".
Jeeps should only have TWO doors.
You should ALWAYS wave at other JEEP drivers.
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Old 04-02-2011, 05:45 AM   #20
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Lol yea your right
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Old 04-02-2011, 06:57 AM   #21
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outside looking in here...but you can learn to weld body panels but it takes practice, Its not like welding lets say a bumper..you want to do stiches with a little here little there method allowing some cool down time also.
its a learned practice, everyone had to learn at some point. That being said depending on the type of repair the OP needs I wouldnt recommend taking this one on yourself, only because the area the repair is. this patch panel has a logo stamped in it (jeep) and if you do get a little carried away with your heat its gonna be a little hard to drag your filler out far enough to correct it. However I dont know your abilitys or equipment you have on hand, You could always find a local shop to weld the patch panel in for you (if needed) and you could finish the repair on your own.
I do think 10 people are gonna have 10 different ways of approaching a repair not that any are wrong. and some I have found area specific. those of us living in the rust belt will aproach rust repair different then someone in lets say Arizona. Good luck
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Old 04-02-2011, 08:06 AM   #22
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Very well put
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Old 04-04-2011, 09:25 PM   #23
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I am doing a body off on my 94 YJ and I am wondering how the side body panels are attached.
Are they glued? Welded? Combination?
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Old 04-04-2011, 09:34 PM   #24
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I am doing a body off on my 94 YJ and I am wondering how the side body panels are attached.
Are they glued? Welded? Combination?

The side panels are spot welded on. There is a flange on the floor pan and around the fender wells that turns down to have about a 1/2" flat area that the panel spot welds to very few inches. At the connection point above the "jeep" logo there is a flange that turns in and is spot welded. Same where it meets the rear corner. It will be spot welded to the main supports as well...just in front of and behind the door.

There should be some seam sealer in there but should come out pretty easy.

They sell a spot weld remover tool that attaches to a drill for easier removal. I just finished welding new panels on my cj.
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Old 04-04-2011, 09:40 PM   #25
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Originally Posted by wrangler yj View Post
ok thanks im not sure yet if i should grind the spot out or if i should just replace the whole panel.
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If you just grind it down till the rust is gone if it's not all the way through then you need to put rust mort on it
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There is no better way than to cut out the rust and replace the cancerous section with new. Do it right, do it once.
Depends on the level of rust.

I have done the weld through replacement. My drivers side was gone. I replaced both panels on my cj. The passenger side was a NOS panel so had the jeep stamp so I cut the original passenger side jeep and welded it on the drivers side.

My panel did warp some but not much more than the rest of the panel since I spot welded it on the way it was new. I also weld very cold. Pretty much bottomed out.
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Old 04-05-2011, 06:06 AM   #26
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[QUOTE=Dempsey;1158116]The side panels are spot welded on.

Thanks, that makes it easier, next step tear down

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