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Old 06-26-2012, 11:37 AM   #1
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Default Rear frame rail fix

Hello!

I've got a 99 XJ Sport that I picked up to tow with. I've now discovered that the rear frame rail is rusted out below where the fuel filler hoses go through the rail. That big hole in the frame rail seems like a pretty poor design decision to me.

Wondering if anyone knows of any product (or maybe can fabricate one themselves) that would be like a bracket/support piece to go over that section to reconnect and solidify it. My internet searching has turned up nothing. Thanks.
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Old 06-26-2012, 11:41 AM   #2
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This will be locked in a few minutes so I'll hurry.

Cut all the old stuff out, replace it with new metal.

Done.
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Old 06-30-2012, 01:39 AM   #3
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Really surprised this hasn't been moved yet
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Rest in peace Brian "96_XJ" Perrine. You will be missed by all of us. Thank you for all that you have done to help make this a stronger forum.

XJ is gone, but not forgotten. JK build in progress.
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Old 06-30-2012, 12:15 PM   #4
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Build a fresh box section, I added couple formed pcs top and bottom of the box to strengthen. All 16ga HRS, overlapped, all seams welded, then secured to frame with formed angle sections, all overlapped and welded all seams, 3 layers gives you 3/16". Weld to floor also, replace floor if required. Paint all with a rust paint (you can't future weld thru spray rubber or ashpalt based coatings). Still workin great for me 1 year later. Lots of pics in my album section. Remember to remove tank and all flamable materials/fuels. Have a buddy of fire watch while welding.
Got any pics of your current condition?
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Rear frame rail fix-img_1793.jpg   Rear frame rail fix-img_1794.jpg   Rear frame rail fix-img_1798.jpg   Rear frame rail fix-img_1796.jpg   Rear frame rail fix-img_1937.jpg  

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