Yeah, rust was eating all the way up to the fuse block. Do you have any idea why it would rust up there? Do I have a leak? Other side is totally clean.

 

Working on cleaning up the the engine. I needed to replace the valve cover gasket and oil filter adapter o-rings. While I have the valve cover off I painted it and a bunch of other parts including the fuel rail and manifold.
This is what I started with.



You can see the oil leaks making it look like I have a main seal leak. I might, but If I do, it's not enough to matter.



New gasket. Fel-pro perma-dry.



New ballast resistor from Quadratec.



New Dorman radiator fan.



Here it is all put back together. I should of taken more pictures during the process, but I was in a rush.






I still need to clean the engine bay, but I guess if I paint stuff as I replace it eventually the whole bay will be super clean.

 

Finished the driver side floor! Huge moment for me. All the inside repair is done.

Rear driver side. All the rust cut out. Unibody rails treated with Rustoleum rust reformer, then fluid film just like the others. I did some experiments with welding right near areas with FF, and it doesn't light on fire. It just smokes, so I spray inside before welding the pan on top.




Eastwood weld-thru primer for the lapped areas.



I tried to butt weld everywhere the factory didn't originally have a joint. I didn't cut the trans tunnel too short this time, and I'm pretty happy with it.



Up front I did the same.

Had to fix this spot on the inner rocker





Same frame treatment. Eastwood on the flanges.



I decided to weld the pan in first then fill in the areas around it.

Test fit.






All welded in. Finally the last C2C fab pan is in. I bought them like 6 months ago.




Then all the surrounding bits. Working up in the footwell is terrible.



ALL DONE. FINALLY!



Got it all primed. I used rustoleum brush-on clean metal primer.




Sanded and ready for a thick coat of paint.

 

Looks good!

 

Thanks! In between waiting for paint to cure on the floor, I decided to fix the rusted out downpipe. I couldn't buy a stock one BC I have a pacesetter header, no cat, and a Gibson cat-back exhaust.
There was a rust hole right before the o2 sensor. I suspect the is one of the reasons for the rough idle I had. I decided to purchase a stock downpipe and chop it up to fit my setup. I cut the end that connected to the header off the old pipe and welded it on the new.

You can see I ended up only using a little bit of the stock pipe. I wish I just made the whole thing custom so I didn't have those tight crimped curves, but oh well. I'm not building a race car. At least I eliminated those crushed-in spots the stock pipe has, as well as the cat. I bought the jeep without a cat, so I didn't actually remove it. It came that way.




I painted with high temp paint since I live in maine.



And welded on an o2 sensor bung. The pacesetter downpipe had a Glowshift clamp-style sensor bung on it, and I wanted a more permanent solution.



Does anybody have any idea how much horsepower gain I have from: long tube header, higher flow downpipe, no cat, and Gibson cat-back? I also have a Scepter intake and 4 hole injectors.

 

Just a guess, but probably 10-20 HP.
You could always do a 0-60 test and calculate HP

 

I'm not building a race car, so I guess I'm not too worried about it. Maybe just enough to give it some kick in the pants.

 

All painted! I have begun installing sound/thermal insulation. I bought this stuff from Amazon and it's great stuff. I've already done the walls and doors. Will be doing the floor up to the the rear seats. I don't have any cargo area carpet yet, so I'm not going to do it back there.

It's little dusty.

 

Little bit off track, but I got a great deal on marketplace this morning. I was planning on getting BFG KO2 tires, and wanted the 5 spoke alloy rims I liked best. Might as well have your favorite rims if you are going to get nice tires.
Anyway, I picked these rims up for $25 bucks each. Super happy with them. I decided against doing the 3" lift I was originally planning to do on this Jeep. I'm going to stick with the stock Upcountry set up. Stock rims and 235/ 75R15 tires.
I'll post about replacing the leaf springs and coils later on. I don't want to distract too much from the interior that I'm trying to finish up.

I might paint them so they are perfect, but not sure.

 

Started putting the interior together today. I decided to paint some of the interior plastics since they looked pretty tired. I used Rustoleum Granite, and it was a really close match. Pretty happy how it turned out.

 

Nice result!!

 

Thanks! I was surprised at how well it turned out.

 

Stripped the parts from my set of old doors today. I have the perfectly good passenger door. If anybody wants it you can have it, because I will probably just end up throwing it away. Hate to waste a rare door though.



I also have these vent windows for sale . Let me know if your interested. I am hoping to get $125 for them.

 

I installed sound deadening on the floor. I ran out of the Amazon Basics stuff halfway through, so I finished with Siless Max. I am happy with both products. So, I have done both doors, the rear quarters, and the floor. I want to do the roof, but I am going to wait till I replace the headliner.
Total I used about $100 worth of product. About 60 sq. ft. All I have left is to put in the carpet in and remaining trim, and the interior is done.

 

Was it worth it? Does it dampen the sound a little, or a lot?