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megamega 12-30-2012 01:58 PM

Hello all,
I need some advice for the newly acquired Jeep of mine. It is a 2000 GC Limited 4.7 w/ 133k miles. It has been dealer maintained it's whole life and it running very well. It has lived it's whole life up until 1 month ago in NY and is now here with me in NC. I would like to keep it long term but have been giving it a closer look and have discovered some rust underneath. I would think the rust will slow down now that it is in a milder climate, right? Or should I act on this right away? Or is it ok to just leave it and not run it through car washes with underbody cleaning. Although I am pretty handy (I just changed out the front drive shaft) and I do have past welding experience, it was 25 years ago and I am a little hesitant start relearning on this car. Should I slap on rust converter? Somehow I doubt that will help. I have read about how some folks paint on por-15 but that may be on areas not yet rusted? Here are some pictures. Of the four doors, the front driver is the worst, the passenger front is not as bad. The rear doors are ok. There is rust holes on some areas of the frame on the driver side, the passenger side may also be rusted through, but I have not poked it to find out. Also some of the cross members have rust where they are attached.
Btw, I would not have bought a car like this, it was an inheritance and I guess there is some sentimental desire for me to keep it and maintain it as long as practical especially since it runs so well. Thanks so much for your help!

Scottina06 12-30-2012 02:19 PM

Re: Rust...advice?
some of the frame underneath you could clean up with a wire brush and coat really good with undercoating for a quick cosmetic fix. Ypou could also clean it up by cutting out the rot and welding on some nice steel plates and then coating. The could clean them up with a wire brush, prime and paint. offers spray cans of paint to match and cleatcoat. All of this is a do it yourself....or you could visit a bodyshop.

megamega 12-30-2012 02:39 PM

Re: Rust...advice?
Thanks so much for the quick reply Scott, that is helpful. To be honest I have been itching to get back to welding for a while and now I have an excuse... hehe... so I just may try that approach. What gauge of metal would you recommend?

Gus9890 01-07-2013 04:52 PM

Re: Rust...advice?
Get ya some rust converter and spray it on after you clean it up with a wire brush. It'll stop further rusting and act as a primer. Then prime and paint it after you repair any holes.

megamega 01-07-2013 07:23 PM

Re: Rust...advice?
Thanks Gus. I plan to weld some plates over the holes and clean up the beginnings of rust. I read that POR-15 is a good protector and I have a quart on order now. Do you think that I should I apply the POR-15 onto the bare metal (after wire brushing)? Is there any other prep or over coat you recommend?

Graphicks 01-07-2013 11:55 PM

Re: Rust...advice?
I haven't spent a lot of time under jeeps, but the GM rig's I've worked on used a lot of 16 and 18 ga. for non load-bearing. I found that I could drill 3/8" or so sized holes into maybe 3/16" thick plates and pretty easily use the holes to weld onto the thinner stuff. Might also be a great opportunity to add some skid plates or reinforcement.

kennzz05 01-08-2013 01:22 AM

Re: Rust...advice?
not to be an ass but im sure between google and youtube you could spend a week reading and watching the best ways to handle these issues

Hacksaw 01-08-2013 08:35 AM


Originally Posted by kennzz05 (Post 734303)
not to be an ass but im sure between google and youtube you could spend a week reading and watching the best ways to handle these issues

You say you're trying not to do that yet with several posts from you tonight that's exactly what you've succeeded at being, congrats.

Think Outside !- No Box Required.

kennzz05 01-11-2013 08:34 PM

Re: Rust...advice?

Originally Posted by Hacksaw (Post 734424)
You say you're trying not to do that yet with several posts from you tonight that's exactly what you've succeeded at being, congrats.

Think Outside !- No Box Required.

thank you sir

Gus9890 01-12-2013 11:07 AM

Re: Rust...advice?
kennzz05, I'm pretty sure he knew that, but why put your chances on watching someone on youtube or googling something when you can come here and get multiple answers and multiple ways of doing things that are a hell of a lot more beneficial.

I'd say either rust converter or POR-15 after cleaned up real good, then you'll be ready to patch 'er up without worrying about any residual corrosion.

megamega 01-21-2013 09:24 PM

Re: Rust...advice?
So I have another follow up question folks. I wirebrushed the bottom inner edge of the three doors, got all the loose rust and dust out off and put two coats of por-15 on them. While I was down there i poked around with a screwdriver to survey extent of the rust under the rocker panels since I am planning to weld metal on and need to take measurements. I was not surprised to see further extent along the rocker bottom, but I also discovered that an outer cross beam leading to the rocker has been pretty extensively rotted on the back side and the bottom. :( Do you think it would be ok to remove some of the badly rusted areas on the back side and the bottom of the cross beam and just leave the remaining good side and minimal remains of the other portions and coat everything with primer/topcoat or an underbody paint? This would be easier than trying to reconstruct it as fabricating pieces will be time consuming for me. How critical is that beam and can it do it's job without some of those surfaces? This is the beam that is under the front door, driver side.
Here are some pics.
Front side of beam:
Front side photo by kam3rad | Photobucket
Bck side of beam:
Back side photo by kam3rad | Photobucket

Gus9890 01-31-2013 04:19 PM

Re: Rust...advice?
You should be able to clean that up and patch it with bondo, fiberglass, or aluminum sheeting. It looks like it's surface rot. But if it affects structural support, then you'll probably have to do some fab work.

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