...let me just start by saying that this was how it was given to me. Yes, my father gave me his old 99 xj with cosmetic neglect.

The biggest eye sore and problem I need to address is the rear passenger side panel over the wheel well (fender some would say) he gave it to me with rot and it's since gotten worse(probably from the bumps from wheeling+ mud cover.

I know the panel is available to purchase and replace with a few bolts and some spot welding, but I would like to chip away at the rust and rebuild it... My question is; with what? Don't worry, I'm artistic, a perfectionist, and good with fabrication.... Here's the damage.. It's nasty...



Once I get a few opinions I'll start with the process of rebuilding the fender, and I'll post pics to show how it comes out..

 

that's not rot. that's just a bit of surface rust that is bubbling the paint. our vehicles up here get rot.

remove flare and hit it with a flap disc. remove all loose paint. if the metal is pitted, use some filler or glazing putty, sand and primer/paint.

looks like the door area may be a bit more, but yeah, same steps. maybe a sand blaster can get in the nooks and crannies.

worse case, you may have to replace a bit of metal.

 

that looks like a little more then surface rust to me.

 

Definitely not surface rust.. As you can see, when I push it, it cracks and crumbles

 

ok, that one shows some rot.

i would start by just replacing the fender, find a clean one and a few bolts later, it looks like new.

the rest may be a bit of a challenge.

 

I figure if I can just knock out the rust, prime with rusto, wire mesh and bondo to form a new fender.. I can do it... Do you think it's worth a try?

 

It's in the rear, so no easy replacement.

I did nearly the same thing once, it seemed that after 6-7 months it separated from the metal, maybe because of unibody flex.

 

Interesting.... Despite the fact that this is not good news, this is why forums are the best place for quality input.

 

If you want to get it back to original looking condition I think you have three options: a) you mentioned aftermarket new panels are available so you could get one; b) cut up a JY donor and weld in the replacement section or; c) piece it together manually with sheet metal. I had a subaru with the rear quarter doing something similar and ended up going option b so I didn't have to make the curves.

 

Replace the metal DO NOT just fill it with bondo. Bondo is great if it stays less then 1/8th thick. Cut out the old metal farther back then you need. Then tack new metal in its place being very careful not to over heat. Sheet metal warps easily, grind the welds and lick in a THIN layer of bondo, prime, paint to match.

 

That seems like the best option.... Sweet deal

 

out of curiousity, have you pulled the carpet and checked the floors or gotten underneath it and really looked closely, id be suprised if that rust is all there is. also check out the cargo area floor as well. if you plan on lifting start soaking down all yer bolts now with pb blaster do it once a week till you are ready to start changeing parts

 

 

bondo will crack on impact with rocks even if you had a slider, that is alot of body rot may possibly look into gettin another xj and wheeling this one to the ground