OEJ

i am planning on doing this mod shortly. being on a limmited budget... i was wondering if i could use rtv sealant along with rivets to seal it. then i was going to put some expanding foam inside the well. would this be acceptable. or should i spring the 25 bucks for the seam sealant?
thanks in advance.

Dan91

Expanding foam is an absolute no, most people say it acts like a sponge and absorbs moisture. I can defintiely attest to that. RTV and rivets should work, but won't be as strong as welding it. IMO seam sealer is expensive, and probably worth it if you're planning on keeping it for a long time. Otherwise pick up a tube of PL adhesive from home depot.

P.S. when I did mine I sliced 90% of the material out cause it was so rusty, I welded in a plate of 18 GA galvanized and sealed with regular old silicone.

99 Purple XJ

I used self drilling screws with rtv sealant

clayton3854

when doing this mod did any of you drop your gas tank? a buddy of mine insisted on doing his that way. also whats best approach to handling the side with the filler neck to ur gas tank?

Nickell586

Just start cutting. Its pretty easy. I just sprayed under coat all over it. I'm redoing my rear fenders now and there is no rust in there so it held up fine. I used an angle grinder with cut off wheel but sawzall would be easier in some spots

Dan91

I jigsawed/sawzalled all the cuts for mine so I didn't have to worry about sparks until welding. The gas tank filler isn't affected unless you went pretty high. I kept a fire extinguisher and garden hose nearby just in case, but I had no issue.

OEJ

Thanks for the replies. I have an air saw,grinder and sawzaw. So I will be good there. I do plan on keeping her for a long time. But I think i Should be ok with rtv and rivets. I'm also gonna paint my wheel wells while I have the tires off. Now just waiting for some better weather. I wil post pics when I'm done if y'all want me too.

helmut

The gas tank filler is not affected but the gas hoses that go from the filler to tank are. Take the shield off and than after you do your cut and fold you could reuse it. You will have to bang it flat a little where it mounts but I was able to reuse it. The whole mod is really easy to do and I think it looks awesome.

Gee oh Dee

No need to drop the tank. That seems really ridiculous.
X2!!

DIRTDOGXJ

If you don't want to spend the money on seam sealer, get 3M 5200. Its stronger than rtv and and about half the price of seam sealer.

And expanding foam is a bad idea....it just holds water.

xj^REMY

https://www.cherokeeforum.com/f58/re...rite-up-94546/

riveted & sealed with silicone exterior sealant... maybe not THE best sealing & rust prevention method, but almost a year & endured a New England winter (tho we got hardly any snow) & no signs of problems

OEJ

Thanks for the tip dirtdog. Ill get that.

Xjremy.. I found ur writeup yesterday and saved it. Thanku. Also got one saved from another forum...I forget wich one.lol I shoul be good though. Good lookin.

xj^REMY

this one...

.. what i used for motivation & reference... he also shows how he modified the gas lines' shield

GOOD LUCK!!

OEJ

that be da one.haha. yeah between ur writeup and his...stevie wonder could do this.