So a couple of months ago I picked up this 98 XJ as a project to do with my son. He's 13 at the moment and has a thing for Jeeps.

Obligatory photo for the visually curious.


All was not perfect but overall it was in mostly good shape, runs really well, and I felt it was worth saving.

I had posted a thread before asking some questions about this and that related to rust and received some good advice as well as some warnings to heed related to wasting time and monies on a lost cause.

Armed with that info I gutted the interior to see how extensive the issues were. Well we got lucky.

You see the main issue is severe rust in the uuper windshield frame area.In most peoples eyes this is a deal breaker. We are not most people.

So how did we get lucky?

The floors and subframe are in good shape with the exception of a small area in the passenger side front footwell.

After a few hours of scraping and wire brushing, followed by a quart of rust bullet we are at this point.


Here is the worst of the windshield rust on the passenger side. Before I attacked it with a scraper and wire brush it didn't look nearly this bad. But it's obvious here how bad it really was.


At the back of the roof in the corners this was starting to happen. Again it had been hit with a scraper and wire brush to expose how bad it really is.


I know at this point the lost cause though is bleeding through loud and clear. My thoughts were it would just be easier to replace the whole roof.

So that's what we're going to do. It's been a little bit since I decided to make this build thread but I haven't really had any time to devote to the Jeep for the last 6 weeks with work and other personal stuff going on.

Until today.

Since replacing the roof is the focus now, the first thing I needed to get was a new roof. My local pic-n-save had 4 96+ xj's on the lot. 2 of them had roof damage that made them unacceptable but I found a good roof on this 97 XJ Sport.

After removing the windshield, interior trim and dropping the headliner I started cutting.



While it may appear there is rust in this windshield frame it is all superficial. There are no perforations and everything is solid. No way I was getting a roof with the same issues.

With a sawzall it was a pretty easy process. Minutes later.


Loaded on the truck and ready to go home.


So now the necessary parts are in hand.

The plan now is to brace all the A, B, C and D pillars with square tube framework before removing the existing roof. Then cut keys into each pillar on both the old pillars and new roof pillar stubs so it will only fit one way and add strength when being welded.

I'll update this once I start the actual replacement process.

 

looks good. subscribing for the fun

 

Nice! I’m excited to see how it turns out, subscribed

 

Looks like fun!!!

Hmmm..... Chop top Cherokee.....

 

Not trying to cut you down about this whatsoever because I admire your determination with this project.

You have damage on the good jeep in 2 places and having an entire spare roof to work with. The easiest way to fix would be to cut out the bad and insert the good in those 2 places. Then you only have to remove one rear window and the front windshield. A hell of alot less work. Less cutting and welding.

Just an idea man again not knocking your approach

 

I appreciate what you're saying and it was originally my intention to do just that.

But there is rust in the gutter rails and under them where they meet up with the body above the doors. Not near as bad as the windshield mind you but enough small areas that it will be a real pain to get all the little patches cut out and replaced while ensuring the cancer all around it is gone as well.

By replacing the entire roof I can be sure all the potentially invisible and hard to see rust areas are being removed. I'll also be able to address any possible issues in the pillars at that time too.

Yes it seems ambitious and I'm not thinking it'll be a simple swap but I believe the time invlolved will be less than trying to patch the individual rust areas.

 

That's cool man I get it.

I just hope you take lots of pictures for us to see

 

Sweet, I like it. I've seen several vehicles repaired this way and they were all fine, and it wasn't done with nearly the level of care I suspect you'll be giving to it.

Also, it's interesting how vehicles in the South/Southeast rust from the top down, whereas here they rust from the bottom up lol.

 

I don't know the full history of this jeep but suspect it had been parked under a tree of some sort for a while during it's life. Not recently as the service records I've found showed regular oil changes over the last 3 years.Anyway once the acidity of the leaves leeched through the paint the rust started.

Not unusual for around here. I bought an 07' Mustang in 2010 that had been parked outside and in those 3 years the leaves built up in the rear window drains had already stripped the paint off in those areas. Caught it and stopped any rust from forming but it can happen quick.

Running the VIN on the Jeep it was originally purchased in Utah. How it found it's way out here is probably a story in itself.

 

I love it! Let's see the progess soon!

 

Looks like a wonderful little weekend project.

Stay after it and it will be worth it in the end. I almost gave up on mine twice in the 2 years it took me to get it where it is.
Just had to take a step back for a bit.
But I would not trade it for the world at this point.

Good luck with it.

 

How goes this build. Awesome to be getting for the little man.

So goes the valentine's conversation. " hon may we get a project for our little girl." (4).

Awesome man have a great time. Some of the best times were working on the 4x4 with my dad.