Novak Conversions Jeep Wrangler TJ engine mounts

Rust repair question

Nickfpharmd

New Member
Original poster
Joined
Jan 15, 2023
Messages
9
Location
Hartford, CT
Hello to my friends in the Northeast and anywhere else with salted roads in the winter.

Bought a 2000 4L TJ Sport last year that’s in mostly great condition. It spent most of its early days in FL, but has spent some amount of time up North with the previous owner. Been tackling some minor rust spots but found a more significant area under the passenger door on the body the other day. Pics attached.

I was poking around and the bottom piece just crumbed. I removed as much of the rusted metal as possible.
Looks like it exposed a cavity in the tub. I grinned out as much of the rust as possible with a wire brush and Dremel. Then cover all surfaces with Coriseal.

Question: how best to seal
The area back up. I’ve not welded before and was wondering if a high strength Bondo might work over a mesh plate locked in place. Thoughts and recs?

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I think you need to take a hard look at that frame.

No to mesh and bondo. That's a structural part of the tub that needs repaired with proper patch panels, weld through primer.

Go buy a cheap MIG welder and some .023 wire. Nows a great time to get a Black Friday deal. Everlast makes some good machines. Harbor freight and Yes Welder...so many choices out there.

I use a 25 year old Miller and just bought a Everlast plasma cutter.

-Mac
 
Thanks! Frames in very good shape. It was repaired at some point but had it looked at by a shop after I bought it.

The sidesteps arent coming off. The whole bolts are just spinning. They’ll need to come off for any repair. Any tips for that?
 
Never use Bondo for anything. Never! It uses talc as a filler and talc absorbs moisture.

You can seal that area up by cutting and fitting a piece of steel. Do a search for "body panel adhesive". This crap is so strong body shops aren't welding anymore. Fit the piece, slobber the adhesive on, stick it in place.

As @macleanflood said, Eastwood makes good stuff. But the best rust prevention is cosmoline.

If you are up in the salt belt, you better get busy on protecting your jeep as soon as the tulips pop up or in a few short years you will be driving a heap.
 
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Reactions: macleanflood
Just leave it. No reason to patch it now. Outside looks good. Body mounts look good. Why bother with trying to DIY a crappy repair?
 
Novak Conversions Jeep Wrangler TJ engine mounts