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Old 04-25-2015, 01:47 PM
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Location: Uniontown/Green, OH (NEO)
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New '94 YJ owner.

I've just picked up my first Jeep, and I'm trying to get up to speed on the YJ, but it is going to need a lot of work on the body and frame to deal with the rust. In retrospect, I should have kept looking for a cleaner specimen but living in Ohio that is like finding hen's teeth and this one was local. I primarily bought it for some of the mod's but compromised when it came to the rust on the body and frame - I'm sort of regretting it now.

So, first, what is the best approach to dealing with body rot? Buy complete replacement panels or weld in new steel after cutting out the rust? I'm also thinking of going with tube fenders up front to help with clearance on 35's but both rear quarters and corners as well as the rear valance below the tailgate are in bad shape.

The frame checks out to be solid but it won't be long before the inside completely fails - chunks of metal can be pried out through the frame holes on both sides in the rear. Can this be slowed down with POR-15 or should I save up to have the frame repaired correctly? I can make it through one more winter but it'll be much worse by next year if I don't at least add some protection to the frame.

But, despite the buyers remorse, the YJ is still a lot of fun to drive and I've started with an oil/filter change, new serpentine belt, wipers, replaced burned out bulbs, and got the tire pressure corrected in the 35's so it doesn't wander as much driving down the road.

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Old 04-25-2015, 02:39 PM   #2
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I feel your pain, living here in michigan. As far as the rot and rust, I suggest replacement panels. And frame sections. It can be cheaper than you think, if you look hard enough for the parts. I dont need frame sections, but I'm gonna be doing multiple body panels this summer my self. Good luck, and let us know how it goes.

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Old 04-25-2015, 02:55 PM   #3
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Yea us Michiganders know all about the salt n rust. Depending on your skill level it is always better to cut the rot out. Getting as much of the rust scale off and cleaning as much as possible and then using some por-15 should buy you some time. I can also relate to the buyers remorse, my last yj seemed great for the first 6 months than the true problems began to show through the po's attempt to hide it. Keeping your eye out for a donor tub and frame is always a decent option also. GL
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Old 04-25-2015, 08:19 PM
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You're right about the replacement panels being affordable but I'll need to learn how to weld. LOL
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