Collision Damage
Thread Starter
Junior Member
Joined: Jan 2013
Posts: 70
Likes: 46
From: Louisville, KY
Year: 1994
Model: Cherokee
Engine: Stock 4.0 HO
Thanks for your advice!
I picked up the door today at the salvage yard off a white '96.
I'm going back to the same vehicle in the yard with my sawzall and my fiber cutter to get the entire B-pillar, inner/outer rockers driver/passenger floor as one piece (No Rust!!!!). I have a couple of different-size hacksaws and a smaller reciprocal sheet metal saw to use as well.
There are a couple of mom and pop places that do restoration that have body jigs to straighten things out and also to weld stuff up, although I've doe some heavy arc welding but not this fine stuff.
Thanks for your enthusiasm!!!
I picked up the door today at the salvage yard off a white '96.
I'm going back to the same vehicle in the yard with my sawzall and my fiber cutter to get the entire B-pillar, inner/outer rockers driver/passenger floor as one piece (No Rust!!!!). I have a couple of different-size hacksaws and a smaller reciprocal sheet metal saw to use as well.
There are a couple of mom and pop places that do restoration that have body jigs to straighten things out and also to weld stuff up, although I've doe some heavy arc welding but not this fine stuff.
Thanks for your enthusiasm!!!
Thread Starter
Junior Member
Joined: Jan 2013
Posts: 70
Likes: 46
From: Louisville, KY
Year: 1994
Model: Cherokee
Engine: Stock 4.0 HO
Yup, Going to replace the inner/outer rockers, flooring edges and B-pillar as one piece. Getting a No Rust replacement from a '96 in a salvage yard.
Thread Starter
Junior Member
Joined: Jan 2013
Posts: 70
Likes: 46
From: Louisville, KY
Year: 1994
Model: Cherokee
Engine: Stock 4.0 HO
Thread Starter
Junior Member
Joined: Jan 2013
Posts: 70
Likes: 46
From: Louisville, KY
Year: 1994
Model: Cherokee
Engine: Stock 4.0 HO
My main concerns at first glance would be the inner rocker and B-pillar. How much got shoved inwards, and how bad? The outer rocker shouldnt be too bad replacement-wise. Doors are easy. Check the body surrounding the door hinges, too. Could be a shadow, but the upper right corner of the rear door looks tweaked outwards a bit.
The rusty floor between the rocker and the big frame beam absorbed all the shock!
LOL, I have two new floor pans that I would have put in a few months ago (driver/passenger), but luckily I didn't.
Thread Starter
Junior Member
Joined: Jan 2013
Posts: 70
Likes: 46
From: Louisville, KY
Year: 1994
Model: Cherokee
Engine: Stock 4.0 HO
Believe it or not there was a recall maybe three years after I bought this '94 that the upper drivers side door hinge had to be re-welded. I could see where it was starting to crack. Later on, the weld that the dealer did cracked all the way through so I fabricated a thick aluminum plate that went between the hinge and the body frame ad was fastened with 3/8 bolts. It is still holding very well, although when I start taking the door off to repair the recent collision damage, I hope it comes apart well and will probably have to be redone.
Senior Member
Joined: Jul 2012
Posts: 793
Likes: 104
From: Aldie, VA
Year: 1999
Model: Cherokee
Engine: 4.0
A couple of years ago there was an active member here that rebuilt the smashed front end of his XJ (with pictures as he went) on a budget, without a lot of experience. It was bad, and most of the community told him it wasn't worth it and to dump it. Then in a heartbreaking turn of events, on his first test drive after the repairs, he got hit by another vehicle, smashing the front end again (this time on the other side). He rebuilt it again (with pictures), while most of the community told him it wasn't worth it, and to dump it.
I don't know if he is still active here. But his posts really changed my thinking on things. Not just with cars, but with life in general.
.
I don't know if he is still active here. But his posts really changed my thinking on things. Not just with cars, but with life in general.
.
Senior Member
Joined: Jul 2012
Posts: 793
Likes: 104
From: Aldie, VA
Year: 1999
Model: Cherokee
Engine: 4.0
So glad to see it is useful for people. Was one of the most frustrating and satisfying projects I have ever done. Definitely got extremely lucky both times on the hits. A few inches difference on either side and it would have been into the frame and body structure for sure.
Thread Starter
Junior Member
Joined: Jan 2013
Posts: 70
Likes: 46
From: Louisville, KY
Year: 1994
Model: Cherokee
Engine: Stock 4.0 HO
Starts Here
Replacement Body
I like your reply to my post. Very Encouraging.
I just cut an entire section out of a white '96 today (I will post picture). Entire rocker panel, driver and passenger floor outboard of the chassis beam and B-pillar-One unit.
I rented a generator and took my sawzall and other power tools to the salvage yard.
Last edited by Brunette Mom's Hubby; Oct 8, 2019 at 09:28 PM. Reason: Add Photo
Senior Member
Joined: Jul 2012
Posts: 793
Likes: 104
From: Aldie, VA
Year: 1999
Model: Cherokee
Engine: 4.0
Wow. I am truly impressed. Looks like you are well on the way to getting that fixed right. I am really amazed at how repairable these Jeeps really are. I was really surprised how adjustable the doors were too. I had to fiddle with the drivers door quite a bit to get it close right. You can adjust the fit at the hinges and also at the door catch. The door is really heavy so make sure you don't drop it when you unbolt it. The interior trim comes off pretty easily too. You should be down to welding condition in a few hours of work. Can't wait to see your next update. Chumba Wumba the 2nd.
Senior Member
Joined: Jul 2018
Posts: 672
Likes: 28
From: Evart,Mich.
Year: 2001
Model: Cherokee (XJ)
Engine: 4.0
I say if you ain't scared to jump in then no problem anything can be fixed if the want too and willing too is there! everybody told me mine was a waist of time but now is a daily driver just shy of 5000 miles since rebuild! and drives like new 
Thread Starter
Junior Member
Joined: Jan 2013
Posts: 70
Likes: 46
From: Louisville, KY
Year: 1994
Model: Cherokee
Engine: Stock 4.0 HO
Used a comealong to pop open the door by pulling out the rocker panel on the bottom. The rocker panel was squished very tight against the door. Used a 4' length of 3/8" chain and two 8" C-clamps with the comealong and the tree strap..
I knew the only tree in the back yard was going to be good for something
Cutting out the rocker panel underneath the door.
Pulling out the A-pillar after cutting out part of the rocker panels. Need to come out 2.5 "
Hinges are OK.
I saw your rebuild....Impressive!
Last edited by Brunette Mom's Hubby; Oct 22, 2019 at 09:44 PM. Reason: New Stuff
Thread Starter
Junior Member
Joined: Jan 2013
Posts: 70
Likes: 46
From: Louisville, KY
Year: 1994
Model: Cherokee
Engine: Stock 4.0 HO
Correction: 'a white 96, rocker panel/pillar assembly, drivers and passengers side and attached floor (to edge of channel beam).
Last edited by Brunette Mom's Hubby; Nov 17, 2019 at 07:16 AM.
Thread Starter
Junior Member
Joined: Jan 2013
Posts: 70
Likes: 46
From: Louisville, KY
Year: 1994
Model: Cherokee
Engine: Stock 4.0 HO
The salvage piece need to have the spotwelds cut to expose the original mating surfaces. Although the rear part of the rocker panel, I built up using part of my old rocker panel. Hobart 140 Mig, 0.030 wire; Ar-CO2 gas. I should have brought my spot weld cutting kit to the salvage yard so I wouldn't have butchered the rear part with the sawzall.
Last edited by Brunette Mom's Hubby; Dec 2, 2019 at 06:23 PM. Reason: Comment
