I decided to use some of my free time to repaint my back bumper today, but when I took off my rear passenger side bumper end cap...I found this absolutely massive rust hole. Anyone have any advice/suggestions/experience with this sort of thing?

 

Time to weld in a patch panel or if your lifted do a cut and fold.

 

That's way beyond a cut and fold. That entire section, back to the very back, is shot and needs to be replaced.


98, you need to cut out all the old and patch in the new. Whether you weld it in or just cobble something together depends on your budget and the result you want. Remember these important things about rust:

1. It's never lonely. Where there is some, there is more.
2. It's always worse than you think.
3. It never sleeps.

I'd be looking over the rest of the vehicle to see what else needs repair, then getting a quote at a body shop. Unless you can weld sheet metal yourself, of course.

 

Mine had a hole in that area too but it wasnt that bad. That is very bad. It's going to require quite a bit of work to repair

 

3 ways

1) buy replacement sections and weld them in..if they are available

2) cut out the relevant replacement metal from a wrecked one...if you can find one that isnt rusted

3) fabricate the metal sections, and mig weld them in like a jigsaw puzzle...takes some experience

or some combination of above

 

Hmmm. My wrecked 97 would be a match. I can take a look to see if it's rusted. No promises, but I can snap a few pics if you want me to. It would cost you shipping only from 22601.

Let me know.

But really, check out the other side and the rest of the beast, first. It's likely there's more.

 

Your easiest route is a cut and fold. Yes, you’ll still need to add some new material, but a cut and fold will hide inexperienced bodywork nicely.

Of course if you’re going to put those ugly *** caps back on then cut all the bad stuff out, cobble up a patch, rivet or weld it in, seam seal, paint, re-instal the caps...done.

My lower 1/4’s were bad too (passenger was worse that driver by far). I did the cut and fold. Having said that, I’m lifted so it doesn’t look weird...lol.

 

Thats a good way...I forgot cause they wont let you do such mods for a road registered vehicle without an Engineers certificate.

Having said that, extremely good repairs can be done by using a cut section..so long as you are handy with a spot weld cutting drill, and mig welder

Its also amazing what you can hand form from flat sheet metal, using basic items

 

Wow....where do you live that you can’t trim the bottom of the 1/4 panel?! There is no structural needs there, it is not safety related...?!

Only “legality” item I ran into at inspection time was flares. Tires cannot be “un covered”. That, and we do have a height restriction (30” to the lowest part of the highest bumper). I’m at 29 5/8” at the bottom of the rear bumper...lol

 

I think you are right!,,, here is our regulation

Example not requiring certification: •Fitting wheel tubs where structural modification of the vehicle is not required

Live in NSW, Australia, any lift over 2" or tyre size greater than +1/2" larger technically requires an engineer cert..largely ignored, but can leave one uninsured

Cops will also pull you for a vehicle that looks obviously modified and check

When I spoke to a few owners about their "for sale" modded XJ, that is the 1st question I asked, is it engineered?, almost all said No, so that was my last question as well

 

That is a serious PITA!!

 

I did a write up on this awhile back. Hopefully it can help you!
https://www.cherokeeforum.com/f51/ru...t-fold-228882/

 

It is a serious inconvenience to vehicle modifiers.

Cost min $750, and its best to work with your certified automotive engineer.

Vehicles has to pass both a brake and swerve test on a track

The benefit is it reduces what I would consider dangerously modified vehicles from being on the road

if the Cops, or Road Inspectors pull you, they will defect your car, meaning it cannot be driven until it complies with all legal requirements

I know for a fact that modified 4wd are "targeted"..and have been personally harassed by Police on several ocassions

You are pulled over for a "Random Breath Test"..and it goes from there...mine is compliant...rant over

 

I have almost the exact same rust hole under my armor. I just got a quote from a reputable body shop for $650.

That’s with no paint. Just sheet metal work and primer, as I’m going to undercoat that whole area under the armor and inside the well anyway.

 

I got to do mine one of these days. I know the passenger side has a golf ball hole but the bottom is not rusted out...yet. I think the drivers side is good but have not looked at it yet.