Test fitting the rear pan.





Everything looked good, plan was to clamp all the seams I could and then rivet everything.

That front floor always rusts out

Did some playing around with sand blasting.

Compressor does not have enough chooch to really make a dent







All just surface rust.



Final pan test fitting before primer.





Had to hand cut the shackle bolt.

Cleaning up surface rust and priming.

The pans came pretty well coated in oil, but had to sit for a couple months before I got primer on them.

I used basic rustoleum primer. Not a huge fan but it does the job.

Great for cutting out the windshield.



Drilled out some rusted in bolts.

Prepping for sandblasting. Only the dash and engine were left in the jeep at this point.

We ran out of blasting media and had to use what we could get. Yes, silicosis, I know.



At this point a couple good friends helped me out a lot. One offered to let me use his automotive shop compressor to run a rented media blaster. The other offered his garage to let me get some paint on it.





Before

After

Inside and underside of all rails was done.

Let the scuffing begin. Im pretty sure at this point I also sprayed all the bare metal down with POR15 acid etch to prep and seal it.

Let the scuffing begin. Got hours of help from a mate who helped me scuff literally every inch of the body and underside. Was such a massive help.

I had tried to get POR15 sprayed right after sandblasting but ran out of time. Ended up having to scuff everything I sprayed so the next coat would bond.



Ended up cutting off and refabricating the seatbelt mounts as they were somewhat rusted through.



Built a paint room.















Time to coat the whole entire thing in 3 coats of POR15

Better than factory.



Time for body work anywhere that got destroyed during sand blasting. The final paint coat will be textured so I had a bit more leeway than most.

Those nice rust holes on the roof that jeeps get.

Patch looks seamless after a good bit of sanding

This stuff is damn good for body work. make a patch and just glue it on. So long as you can clamp it to dry, she will hold.



Before

After

Rocker was gone on this side. I decided to cut most of it out, POR the inside, and then M3 glue a new panel on.





I wanted it nice enough to last a little while, but evenyually I am going to cut the rockers out and weld in sliders.



The seam at the front of the rocker does not look too bad.

Now that POR has sealed all the rust, I can tiger hair over every body imperfection.













I screwed up by not capping the adhesive prior to doing the rocker. Had to take it all off and use a new tube. Apparently you cannot leave it exposed to air even though it is 2 part.

Had to redo the whole rocker again.

Smoothing everything out.

straight enough

Now I had to drill a few hundred rivet holes ~1.5 inch apart so that I had guides when I dropped the pans in. The plan is to de-burr all these with a file, then drill through the pans using a guide. Once everything was ready a rivet would get dunked in paint and then popped.







Hand painting all the misc hardware. (ended up getting a blasting cabinet, cleaning all this up and spraying POR. Hand painting POR is not a great way to go.

Scuffed the entire jeep again so that the POR primer could grab hold.











Can barely see the patch

Next up, scuffing the whole thing again and spraying raptor liner.

No sign of the patches at all.

First hole

And a few hundred more.





Everything fit like a glove.









Some padding and bolts to hold the front pan in place.







Had to cut the top of the pan to get it perfectly in place.

When in doubt, add more rivets.