James & The Sahara Build Thread

What have you used in the past for rust prevention on your frame? When the weather warms up I’m thinking about fluid film the inside and then rustoleum undercoat the frame rails because I think that’s what I did like 6 mos ago. It held up pretty well, but I can see certain spots I might need to touch up.
I bought POR15 and FF although I haven’t gotten to it yet. Was looking to do it over spring break when it gets warm outside again. I am probably gonna to buy rust converter and use that on the hinges. Not 100% sure if I should paint the spots they sat over.
And the jeep looks naked! Get some armor on that beast haha
X2!

Directed towards anyone reading this thread; Should I just clean up the metal under the hinges or clean up and paint that metal?
 
Yeah gonna hit with with some rust converter and some primer then black spray paint well taped off. Looks like the only reason its bare is from the factory. Same as the doors. Thanks @Ranger_b0b
Yup...the area behind my door hinges was unpainted as well. Not sure why they didn't paint it, but its painted now.
 
Yup...the area behind my door hinges was unpainted as well. Not sure why they didn't paint it, but its painted now.
Reading over some forums last night it has to do with the assembly line paint process. The jeep was all put together for the paint with hinges and bolts getting painted and sealed. Once the seal is broken it needs paint asap. Have to help out a family member down in GA today so driving on the interstate with no tailgate, yayyy.. hahahahaha.
 
I have never used por 15 but have used Eastwoods Rust encapsulate, just ordered some to do the jeep underside when it warms up. I have used it on my 74 TR6 underside in both the primer red color and black and goes over anything and has not flaked off.

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I have never used por 15 but have used Eastwoods Rust encapsulate, just ordered some to do the jeep underside when it warms up. I have used it on my 74 TR6 underside in both the primer red color and black and goes over anything and has not flaked off.

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I love the eastwood stuff, just got a really good deal locally on the POR15.
 
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You got your work cut out for you. Oh, and Jimbo, your butt crack is showing. Hehe!
Gotta love that crack ;).

Seriously gonna be some hard work. I didn’t think I needed to paint the slider step but I think it will rust if I don’t. The tub rails are also stainless steel but a different type. Its difficult to explain. Going to get up early and get it done tomorrow!

Also I misread the savvy email, everything came but the tailgate/valance armor. That ship date is the 31st. So for now I will get it all put together then remove the tailgate again when I get that :).
 
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Well the package came after nightfall, so I didn’t get much accomplished, just some more prep:

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Late at night came the package, UPS guy wasn’t too happy:

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Came with the expected scratches and bruises. Hoping to get a large portion of this knocked out tomorrow!
Great looking prep and armor! Hope you have a great day! I’d love to be there to hand you wrenches and watch it build up. If you get a chance, I’d love to know the weight of the Savvy Rock Sliders (1 is fine) and later see the install from the sides and especially underneath. Great work James!
 
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Lots done, I will say by far the rockers are significantly harder to mount up than the corner guards. The corner guards are more forgiving. I am communicating with Gerald but missing two tailgate hinge plates so the tailgate can’t go on till i get them. Instructions say a nutsert tool is included but after starting this morning Gerald said it is no longer included. Many trips to ACE. I will say all the hardware included is suggested hardware and you really need to think out where and how things mount together. I decided to install one full side armor at a time, because the rockers too so long hahaha. Here are some installation photos:

Mounting up the rockers for center punch:
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Mounted to step to get an idea which hardware was used where:

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All holes drilled:

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Nutserts, meh...

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Mounting of the rocker:

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Inital placement of the rear corner guard:

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Measurements and fitment on POINT:

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All holes drilled:

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Re-installed armor to start mounting:

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Sadly no matter how hard I tried, the corner guards and rock rails did not match the corner curvature, close, but not perfect:

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Rock rail installation is not intuitive lol:

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Final checks of hardware:

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Every hole lined up perfectly except for the license plate holes (yes the light bolts fit perfectly), this is a non issue as I’m going to install the license plate in a more unique manner:

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Really did not see a point of this first intial corner guard mounting point and the rock rail. All of the bolts of the rock rail tie in with the alumium plate for strength and then you have this weird hole, more than likely intended for a nutsert. I didn’t see the need to drill this hole here and mount a screw to sheetmetal. The backing plate is unbelievably strong on the rock rail, I’m impressed:

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Armor installed on the driver side:

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I need to buy a dremel and fix this, slight trimming of the front fender is required for a flush fit:

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Rear fender was quite some work to get mounted up, thanks to quality mountig options from the factory I got it sorted out:

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Fenders installed! The lighting poor but it looks damn good!

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I don’t know if its my spare tire being off or what but I have a SUPER RAKE going on. 2.5” true lift in the front, 4” in the rear. What.

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Rear of the TJ showing both sides:

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My room mate took this picture of the armor that does it little more justice:

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Really impressed with the quality of the armor so far though. 10/10 would recommend hahahah. The next side tomorrow!
 
Great looking prep and armor! Hope you have a great day! I’d love to be there to hand you wrenches and watch it build up. If you get a chance, I’d love to know the weight of the Savvy Rock Sliders (1 is fine) and later see the install from the sides and especially underneath. Great work James!
Let me know the photos you want, the weight of the shipped sliders with step was 84lbs. Super solid. I can weight the one I have not installed, just let me know if you want me to.
 
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That's all I need.

WOW just slipped out of my mouth when I saw your Jeep with the sliders and corner armor mounted. OUT LOUD I just said it. So it is WOW!
 
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