2000 Sahara Wreck Rebuild

Beachhead

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Original poster
Supporting Member
Joined
Aug 30, 2021
Messages
92
Location
Chico, CA
Several years ago I got this 2000 Sahara, and around December last year I felt like I was just about done with it. I had rebuilt the transfer case, repainted and replaced most of the dented body parts that were on it when I bought it, replaced the steering box, radio, wheels, put some armor on the rear to cover a dent in the rear passenger quarter panel, headliner for the hard top, new cylinder head, plugs, battery, radiator hoses, regear from 3.07 to 4.10 and a new eaton e-locker and true trac. A lot of time and money put into this thing, and only 44,000 miles. Plus blood sweat and tears of doing all this crap.

Last picture of my Jeep before the accident:
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So a friend of mine convinced me to go up to our usual spot in January, and long story short it ended with me being sandwiched between two vehicles after sliding down the road backwards while another vehicle came sliding at me from the front. Horrible day.

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I fought and fought and fought AAA to not total my Jeep, they wanted to give me $12k for it and the price I paid plus everything I put into it was about $20k.
Finally, they relented, got the Jeep appraised for $20k and kicked it out of total loss and paid me the bodyshop estimate.

So now comes the job of trying to get it back to where it was.

The original plan was to cut out the passenger side of the tub and weld in replacement panels from a scrap tub, but the damage to the tub ended up being too extensive. The entire back section was badly warped, the floor was buckled, the wheel wells separated from the welds. The tailgate was also smashed from where my spare tire went through it, hard top cracked and window smashed, front passenger fender was smashed but my warn bumper held and the frame was undamaged. The majority of the damage was too the body where the bumper of the vehicle behind me hit the armor. My rear tire carrier was also pushed forward and bent.

I think the posion spyder armor plates I put on the back of the jeep to cover up previous damage actually ended up contributing to making the damage worse, because it added a very stiff push plate instead of crumpling like it would have normally. I'll never put armor on the back of my vehicle again.

Due to the damage to the tub, I decided to do a tub swap and replace the other pieces as needed. So after again much headache and the bodyshop refusing to do the tub swap, the yard in Sacramento that sold me the tub said they could swap it out, so I relented and had them do it. After two weeks, the tub swap was done and now comes the task of repairing everything else.

Jeep after tub swap completed.
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I was able to locate a passenger side door which I need to paint, a new fender, a new fog light, and a tailgate. So i'm working on fixing those up and getting those installed.
Still trying to figure out what to do with the hard top. I believe it to be repairable, and it will need new glass and a few parts on the back that broke like the plastic piece that goes on the bottom of the glass. Or I can buy a new hard top, which are proving very hard to find in good shape.

During the process of trying to fix everything, a few issues have popped up which I wasn't expecting.
First, the hood now sits at a slight angle. If I look at the jeep from the front, the passenger side sits slightly lower than the driver side. Not sure what to do here.
The driver side door which i thought was fine I also think is damaged because it does not sit flush with the body any longer. I put a straight edge on it and it exhibits a slight curve, so it must have been warped during the wreck. I don't know if this can be bent back into shape or If I just need to find a new door skin. (also hard to find)

I'm starting to think I should have bought a cheap high mileage Jeep and just swapped over the running gear and motor, instead of trying to put the body back together, but too late now. If anyone has any tips on how I should best proceed with this project i'm all ears. I know a common opinion is that "it's a jeep, it's supposed to look like shit" but I just can't adopt that!

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Its possible your frame is bent. Some time on a frame rack to measure it would help. You could go the string/plumbbob and tape measure route with the help of this, possibly.put it on flat level concrete and mark the floor.It would still need a rack to fix if bent
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I wouldn’t think the door is the issue. If the tub used in the swap was also in a collision it could be tweaked slightly. That area by the door latch is surprisingly weak.
 
Good on you for fighting the InsCo - fuckers ALWAYS want to "total" perfectly repairable vehicles. I've fought that battle TWICE now. Bastards.
 
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Work continues on the Jeep. I was able to get the door lined up properly, the striker seemed to be installed either upside down or too far forward. I made some adjustments and it's much better now.

I also found out why the fender isn't lined up properly.
The people that did the tub swap said that they couldn't get the new pass fender to fit, so they had to enlarge some of the bolt holes on the fender. They claim because it was from a different year jeep there was a slight offset, which doesn't seem right to me, so now i've got to take the fender off and figure out how to correct for that.

Another problem has also popped up, which is my transfer case which I just rebuilt last year (and changed the output seal on the transmission) has started to leak again. It was fine for several months after the accident, but about a week or two after the tub swap i've noticed it starting to leak. Both from where it mates up to the transmission, and from the transfer case seam itself which was sealed with gray RTV. I'm guessing the shock of the hit, or some other pressure from changing the tub has caused this, so my current job is taking the transfer case down, apart, and resealing everything. Hopefully that will fix it.