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Old 04-06-2015, 08:11 AM
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Molding in aluminum diamond plate to body with bed liner

First a little background info:
I live on an island (St.Thomas VI) so everything I want or need is more expensive and takes more time because all parts need to be ordered.
Recently I bought a 93 YJ as a project because it has a sound 4.0L, 4:10 gear and a new manual transmission. All are hard to find here. Jeeps are really popular and way more expensive than anywhere else I've lived but for some reason most of what you see is 4cyl autos (Worst idea ever for all these hills).

With that being said, I grew up in the south so I'm familiar with custom and hands on work, another good reason to grab an older simpler model jeep because it's next to impossible to find a reliable decently priced mechanic here.
Down here the salt in the air pretty much ruins everything metal so obviously I have several rust spots and body issues.

MY PLAN:
I want to put bedliner down on the inside and outside of my entire jeep. It makes perfect sense here, rains all the time (waterproof ), fender benders are quite common, and it's impossible to find someone to repair my body and repaint it. Likely that whole process would cost 2500-3000 here...not happening.

Here's what I need opinions on. I've read all the forums on here about bed liners so I came up with a plan. I intend to use 36"◊36"◊.025" aluminum diamond plates to cover up certain areas inside and out. Inside between the ribs on the floor I'll use flat insulation strips for noise and heat plus give it a flush fit. On the outside I plan to just put it right over the body. I'm going to use stainless flat head screws.
Now here's the part I haven't found anyone else doing yet...once all the sheeting is added I then want to bondo the edges smooth (if necessary, it's thin aluminum), then apply the bed liner over the top of the remaining exposed body and the aluminum sheets at the same time to sort of mold them together and give it a custom/built in look. Two birds with one stone.
I need some opinions and advice. Will this work like I'm thinking? Will I run into any issues? I know I must properly prep the aluminum and intend to prime everything plus the normal body prep. It will never be necessary to remove these aluminum panels so why not mold it in? I think id have my own custom look too. Please, advice is needed. I've got a lot of work ahead of me and could use the help. Thanks in advance.

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Old 04-06-2015, 11:39 AM   #2
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i cant see it blending real well.. if your rust is on the rockers you can make some rock slider to go over them and it looks good.. i would say just patch them and check out monstaliner i plan on covering my whole jeep with it

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Old 04-06-2015, 12:32 PM   #3
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Your best bet is gonna be to learn metal working. You can't just cover the body with aluminum and bondo. You're thinking seam sealer which is going to be needed. Correctly cut out the extreme patches of rust and weld new metal in and treat the less severe areas with POR-15 or Ospho.

As far as bed liner, I'd use it on the frame and inside the body. I would still paint the outside. A decent gun and air compressor is not terribly expensive and a good investment. Any fender bender could take a chunk out of the bed liner coat and then moisture is sandwiched between two layers of bed liner and the metal in between for the tub.

I'm sure I'm leaving things out lol
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Old 04-08-2015, 09:50 AM
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Thanks for your input guys...first I want to stress to you the importance of my "I live on an island" comment. This means I don't have access to most of the things we are used to having...thus the diy extensive work. I have to conform to the resources I have and anything that's not here would have to be ordered. That being said you can basically double the costs.
Also, I'm not looking to just cover rust spots. All rust areas will be removed either by cutting, sanding or chemically. Once it's removed I planned on covering problem spots with the aluminum, use adhesive and screws to seal it in place and then sealing it in with the bed liner.
In reference to the paint job idea...unfortunately if I wanted it done right here, a full body prep and repair followed by a standard paint job would be well over 3k here. Not an acceptable option (and would likely come out half ass with a short life span)...that's one of the reasons I'm putting bed liner inside and out.
I know it sounds like I'm cutting corners but I assure you, I'm spending weeks on body prep and design, I just can't do things the normal way here. I mainly wrote on here to see if anyone has experienced doing this and if anyone has advice on the procedure I currently have planned.
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Old 04-08-2015, 11:33 AM   #5
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You can go to a website www.eastwood.com. They have a product called rust encapsulator. It works phenominally. I am not sure if they ship to the Virgin Islands or not but that is a very excellent product to use.

It gets painted (by brush if you choose) right over the rusted areas, it chemically bonds with the rust and turns it into a smooth paintable surface.

As far as your ideas of wrapping the body with 1/8" diamond plate aluminum, there is a website for that as well. www.jeepdiamondplate.com unless you are into cutting aluminum diamond plate, which by the way isn't very easy to do. I made custom inner door panels out of diamond plate aluminum, and 42 cutting wheels later with my 4.5" grinder and I got them done.
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Old 04-08-2015, 02:57 PM   #6
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Quote:
Originally Posted by 0III0forlife View Post
You can go to a website www.eastwood.com. They have a product called rust encapsulator. It works phenominally. I am not sure if they ship to the Virgin Islands or not but that is a very excellent product to use.

It gets painted (by brush if you choose) right over the rusted areas, it chemically bonds with the rust and turns it into a smooth paintable surface.

As far as your ideas of wrapping the body with 1/8" diamond plate aluminum, there is a website for that as well. www.jeepdiamondplate.com unless you are into cutting aluminum diamond plate, which by the way isn't very easy to do. I made custom inner door panels out of diamond plate aluminum, and 42 cutting wheels later with my 4.5" grinder and I got them done.
rofl grinder..and diamond plate.....does not go together. use a jig saw or air saw. med tooth blade..more teeth..finer the cut. I've made several custom pieces for many projects. cut on the flat back side.take your time.

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