Rust issues with 81 Cherokee

[cherren]

Does any know of a thread or forums where rust repairs have been done on the upper door sills/rails ?? where the door rubbers fit onto. please see attached pic.

many thx

[TOYROX]

The mounts for the roof racks use to leak. the was the root cause for rust in the roofs of FSJ's.

[alexander]

hi, i repaired exactly that sort of rust on my jeep. first, i cut a profile of the rusted metal out with a small hand grinder, and took it to a sheet metal worker. i asked him to replicate it, which was done with two pieces of bent sheet metal, spot welded together. i had him include an extra flange to allow me to attach the new piece to the remains of the car. i then cut the rest out with the hand grinder. i tacked welded the repair piece in with a mig and added some small stainless screws and rivets where appropriate. ran seam sealer along the joints. sprayed tons of Killrust epoxy paint in from inside. as for the roofrack, i got rid of those stupid rubber grommets, drilled real mansize holes through the roof rack brackets, and bolted the whole thing firmly to the roof. with loads of sealer. i also took the metal strips off the roof, and reattached them with sealer on each screw hole.

i am overseas for a few weeks, but will post pictures of the finished job, and the profile i had made, when i get back.

cheers.

[Jimmyb]

I would look at doing what Alexander suggests. I had to do similar in an old XP I had. You will be amazed what a sheet of metal, pop rivits (or Tig) can produce with some patience. I guess the lucky fact is its under the roof lining so wont be on constant display.

[cherren]

Originally Posted by alexander

hi, i repaired exactly that sort of rust on my jeep. first, i cut a profile of the rusted metal out with a small hand grinder, and took it to a sheet metal worker. i asked him to replicate it, which was done with two pieces of bent sheet metal, spot welded together. i had him include an extra flange to allow me to attach the new piece to the remains of the car. i then cut the rest out with the hand grinder. i tacked welded the repair piece in with a mig and added some small stainless screws where appropriate. ran seam sealer along the joints. sprayed tons of Killrust epoxy paint in from inside. as for the roofrack, i got rid of those stupid rubber grommets, drilled real mansize holes through the roof rack brackets, and bolted the whole thing firmly to the roof. with loads of sealer. i also took the metal strips off the roof, and reattached them with sealer on each screw hole.

i am overseas for a few weeks, but will post pictures of the finished job, and the profile i had made, when i get back.

cheers.

look forward to the pic's, I had a hotrod body builder lined up to do something similar but would rather do it myself as a part of the restoration

many thx

[MR EXTREME JEEP]

If you cant be stuffed fixing it.
http://www.ausjeepoffroad.com/forum/...anted+fsj+rust

[FSJ]

cut the roof off & weld on a newer one.