Body Repair - How to go about

[jMedia]

Now I'm a complete noob when it comes to body repair because i can't really find anywhere to learn (other than just cutting into Baloo:eek: ) but I've often wondered how I would go about the repair below. There seems to be a bit of rust(can't tell too much cause i havent removed paint) but I'm not sure how i would go about replacing that metal seeing as how it is right against a window and part of a pillar.
Any suggestions?

http://www.surfphotosd.com/photos/558611662_iLH4P-L.jpg

[Brizio]

You should take a flat screw driver, remove all the "bobble" and put some Por15 or similar stuff. This will helps to stop it.

[rixcj]

If you plan on doing this repair yourself, the first thing you need to do is to carefully remove as much of the rust as you can. Try not to "slip", with whatever tool you use, damaging the surrounding area. This would create more work for you. The surrounding area looks pretty nice on your Jeep.

I'd use a die grinder, or a Dremel tool with a wire brush attachment on it. Use two hands, for the best control, and try to remove as much rust as you can.

If the metal doesn't go completely through, that would be good. You could apply a coat, or two, of rust converter. Rustoleum, Permatex, and other companies make them, and are sold at most auto parts stores, and at Wal-mart.

Then, apply a little Bondo, and sand smooth. If you're real fussy, pinholes in the Bondo can be filled with spot putty. Read the putty instructions!

Now comes the tricky part. You have to make a decision, here. A body shop would sand out the prep work, and extend way beyond the small repair area, and end up painting a large area, so the job blends in well.

I don't think that you want to do this. So, you can mask off around the small repair area (just beyond where you finished sanding). Wipe the area with wax and grease remover, prior to masking. Mask it off well, with masking tape, and newspaper, to prevent overspray from landing where you don't want it to. Don't be shy...mask off a pretty wide area. Sometimes, ovrerspray ends up farther out than you would guess.

Now, spray a coat, or two of primer. When it is dry, spray a coat, or two, of paint. Always read the instructions on the can, and practice, a little, if you're not a good spray painter. As soon as you're done painting, pull the masking tape off. This will allow the edge of the paint to lay down, a little.

Always pull the tape off in a direction AWAY from the new paint. At this point, you're pretty much done.

The downside to this method of paint repair, is that you'll see the painted patch, and the edge of your paint repair.

But you have to weigh out the options...see the edge of the repair, or see the overspray of the new paint onto the original paint, which, to me, looks terrible.

This may, or may not last forever, but for a do-it-yourself repair, it's pretty good. Much easier than cutting, welding in new metal, etc.

HTH

Rich

[CutterN55]

I've had some good luck on mine using Evapo-rust and steel wool. I knock off most of the loose rust with a wire wheel first. Evapo-rust eats the rust and really brings the metal back to life nicely without the risk of taking off a lot of metal as with a grinder. It treats the area too. I have used this in a couple of spots on the frame where paint was peeling/bubbling and I have used it on fenders. I just soak the steel wool pad in the stuff and give it a good scrub and let it sit on there for a couple of minutes and then wipe it off with a damp rag and then dry it with a rag and compressed air. Then prime and paint... or bondo, prime and paint if necessary.

[babywag]

Lots of opinions out there, but if you want it gone for good, you'll need to dig in a little deeper.

The pillar and quarter have seam sealer where they meet & I can see rust there.
Also looks like your cargo window opening has rust under the window gasket.

You have water pooling, and if you don't fix that while you repair the rust it will just come back.

[tgreese]

I'm not sure what the architecture of the body panels is from the inside, but I think you can reach the inside of that rust pop by removing the inside panels. In my experience, rust pops (like this) occur where the panel rusts through from the inside. This means you have some way that water is getting into the body cavity. I suggest you inspect the inside of that pop as well as yu can. It may be that the rust is going through the seam adjacent to the pop, and that is allowing water inside the body cavity. Then the rust pop results from the panel rusting though from the inside.

Whatever, you need to stop any leaks that are letting moisture leak into the body cavity. I'd also make sure that any drains at the bottom of the cavity are free of debris. As described abive, grind out the rust and repaint. I'd also do my best to treat the inside of the panel, ina ddition to stopping any leaks.

hth!

<edit> I also see pops along the bottom of the window. This suggests to me that the window seal is leaking into the fender cavity. I'd be inclined to removing that window to inspect and repair the rust. You have to get into the inside of the panel there too, but it's easy to get in under those windows.

[jeeporvis97]

The downside to this method of paint repair, is that you'll see the painted patch, and the edge of your paint repair.

But you have to weigh out the options...see the edge of the repair, or see the overspray of the new paint onto the original paint, which, to me, looks terrible.
A trick for removing that ridge is to prime it, pull back the tape a little bit and wet sand the edge to smooth, then spray it with the color you want trying your best not to hit the tape, if its necessary wet sand it again if there is a small ridge. I'd paint the whole area under the window just to the point where it starts to turn and go straight down, because lighting angles would make the color of the paint in that area look different anyway.

[skeletor]

if that turns out to be rust through you could possibly braze it.

[telecomken]

Please click one of the Quick Reply icons in the posts above to activate Quick Reply.

[jMedia]

Thanks for all the suggestions so far guess, just gotta love this site.

As far as "saving" my paint job, i'm ok with messing it up cause i MAY paint it this summer (that'll be another thread about whether or not to keep the police paint :thumbsup: )

I guess i should have at it and chip away to see how deep it is, is por 15 available in stores or only online? What about the seal on the window, can i just peal that back and have a look?

[babywag]

To get a good look I would remove the cargo window.

They push inward, and just kind of pop out.
You just need to remove the metal trim frame on the inside that goes around the window opening.
Go slow, and do it during the day in direct sunlight to keep the seal nice and flexible.

To reinstall is the reverse, use a thick plastic putty knife to manipulate the seal lip around the opening.

I would venture a guess that you have water leaking from the roof rack well nuts, and possibly the window seal, over the years it caused your rust that you see now.

[jMedia]

To get a good look I would remove the cargo window.

They push inward, and just kind of pop out.
You just need to remove the metal trim frame on the inside that goes around the window opening.
Go slow, and do it during the day in direct sunlight to keep the seal nice and flexible.

To reinstall is the reverse, use a thick plastic putty knife to manipulate the seal lip around the opening.

I would venture a guess that you have water leaking from the roof rack well nuts, and possibly the window seal, over the years it caused your rust that you see now.

I actually have no roof rack, so it must be something else

[Carleysjeep]

Whatever you do KEEP THE POLICE PAINT JOB! That thing is just too cool.

[FSJK]

you Cali guys sure do have a different meaning for body repair. I'd title this thread 'blemish touch-up'.

[jMedia]

Whatever you do KEEP THE POLICE PAINT JOB! That thing is just too cool.

i knew people were gonna start saying this :thumbsup: i'm most likely just gonna repaint it the police colors, or if some one can think of another style police paint i'll do that too. Does it lose its cool factor if I just redo the police paint?

you Cali guys sure do have a different meaning for body repair. I'd title this thread 'blemish touch-up'.

this is my biggest rust spot :D not to rub it in.....