Well, with my son's WJ running well after a week long test of wheeling in the San Juan's a couple of weeks ago it was time to turn to some cosmetic work.
Now keep in mind this won't be as precise as what Robert (MP&C) would do but I think it is turning out about as close to OEM as I can get it.
When my son purchased the Jeep three years ago it was stock and relatively clean but we did notice a small amount of rust starting on the left rear wheel arch/door jamb area. My son removed the body trim and found a buildup of dirt and debris causing the area to hold moisture so he cleaned it as well as checked the other areas around the Jeep with the same removable body panels.
We knew we would have to address this once we got the mechanical aspects of the Jeep ironed out so we pulled it into the shop Friday night and started cutting. I was fortunate that we were able to find a rust panel for the outer skin of the dog leg which we originally thought would be all it needed.
However, once I started tapping with the body hammer we quickly discovered it was more than just the outer panel.
The new rust repair dog leg replacement panel.
Area marked for cutting and spot welds drilled to separate the inner and outer panels.
Pulling the outer panel away from the inner panels and foam.
Outer panel removed and the inner panel's damage revealed.
Not much remaining of the inner panel so a new plan was devised.
Continue drilling spot welds and remove the inner wheel well panel.
Once that panel was removed we found good solid metal once again.
Other than a very small piece at the lower edge which was an easy fix. Small rust area was cut out, POR 15 Metal Prep was sprayed all around the area to treat the last remaining surface rust and the piece cut out according to the template.
Some UPOL #2 weld through coating applied after washing the Metal Prep off and drying.
More to follow.....