So I was cleaning and getting ready to finish up some painting on the underside of my 2000 xj this evening. I knew there was some rust, so I was prepping to coat with Rust Bullet. I went across a section on the passengers side where the exhaust hanger used to be and my scraper went right through the chassis. I about cried.

I have new nut strips and will be installing a JCR gas tank skid so I am curious how big of an issue this is. I was really hoping that I wouldn't run into this but that wasnt the case. Let me know what you guys think.

 

Pictures?

It's on the actual unibody?

Inside? Outside? How big is the hole?

I'd start by moving away from the state that you live in.

Then, I'd take a grinder to the whole thing and find ALL the rust.

Cut away what you found then rebuild it...Completely.

Good luck. I hate rust.

 

well, moving is not an option. Grinding is an option, the thing that sucks is the rest of the vehicle is great. For some reason underneath the exhaust hanger just peeled right off. I am thinking that cutting a section out of the floor and welding in a piece of angle steel might be the way to go. Just thinking out loud.

 

Build it back how ever you want but make sure you get rid of all the rust first. Cut it off, put it in a box and mail it to California.

 

How did you end up fixing your rusted unibody? I have a similar problem on my 98 xj.

 

hey looks like you took a pic of my 97

 

I cleaned it up as best that I could. Blew It all out with an air hose. Built it up with welding wire and ground it smooth. Then I painted it with rust bullet chassis saver. Painted it with black rust oleum. I sprayed ATF inside the frame rails until it ran out of the homes at the bottom using a garden pump sprayer. I then installed my new nut strips and my skid plate. I figure that the weakened spot is sandwiched between 1/4" of nut strip and 1/4" of skid plate so it's probably stronger than it was from the factory. If it continues to be an issue I will pull up the floor and go at it from that direction. Good luck!

 

Hey just found some rust holes in the same spot on my 98. I'm new to welding but like yours the Frame is the only bad part on my jeep. So you sprayed ATF throughout the entire frame rails? Never thought about that, would that help with stopping the frame rot from the inside out? I'm going to be tackling rust proofing and fixing rusty areas on my frame then undercoating the entire thing In the next 2months. I live in Ohio so lots of salt over winter. Thanks.

 

I have all of yall beat with rust, bought the jeep with a reese class 3 out back. Poked all over the subframe for rust and didnt find anything.
Pulled a 2500 chevy out and a stock yj a couple time and it was solid. Next time i went wheelin my buddy's tj on 33s got hi centered and needed a tug, so i threw the strap and bumped him. Heard a loud crack and found the driver side hitch pulled out from where it bolts and took the subframe with it. Lol

I have a buddy that scrapping a late 80s that im cutting bumpstop back, cleaning what left of mine up and welding the that back on it. Then will get rear frame stiffeners and weld them over that.

 

Seeing all that makes me glad to live in Arizona

 

I live in fl! Lmao
It was from up north.

 

As bad as that sucks, I imagine it was rather humorous as well.

 

Oh dude it was funny as hell. I got tow hitches as gag gifts.

 

This happend to me pulling my buddy's Toyota out

 

the only way to properly fix it is to for one, cut out ALL the rust. and i mean everything. after that, you need to reconstruct the frame rail. i used sheet metal, a total of 3 layers.

http://naxja.org/forum/showthread.php?t=1064643&page=2

more pics and my explanation go on to page 3.