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Old 08-21-2010, 10:26 PM
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WWI Flying Ace WWI Flying Ace is offline
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Frankenstein FSJ

So, I’ve been planning this project for a while…Got the Beast (81 Wagoneer with a 360 and a 4 inch lift kit) in March. Rusted out rockers panels (no surprise there!) Got a great deal on it though. Rust underneath, but my shop looked it over and said the frame is ok, it is just surface rust. It does need a new gas tank skid plate, but that is in the future. My shop gave me a quote for the rust…I know they do excellent work but I’m only going to have them do the stuff I could never undertake, like getting the AC working again. There is a guy in the AMC club here that had AMC NOS rockers, but he wanted more than I was willing to pay for them. I am sure they were cherry parts, but here’s the thing…I’ll never see a dime back from this vehicle. I just can't see spending way too much on repairs.
As for the frame rust, and the rocker panels…Recently I found the Eastwood catalog…been looking at their rust encapsulater, etc etc. Looks like great products, and I was getting ready to take the plunge…was going to get the frame paint they have, and the rust encapsulater. Then, I was going to spray on truck bed liner on the bottom foot or so of the doors and on the whole underneath. Was going to paint the exhaust with their special exhaust paint too. That was the plan.
The I discovered JC Whitney and Carparts.com. THEY have purpose built rocker panels for $25 bucks each. Plus the shipping because they were a little heavy…it was about $80 bucks for both sides. And, they don’t require you to take the old rockers off, you just slap these suckers on overtop. They get “welded, riveted, or screwed on”. I found at Home Depot and Loews they have rust converter too, it isn’t “official automotive rust conversion spray”, it is from LockTite and it is $2 bucks less per can. And, they have the rubber coating in a spray can too…it is not “official truck bedliner” but it is exactly what I need. And, I got self tapping metal-to-metal screws. This is perfect, because I cleaned out the garage and the basement of all the unopened leftover home improvement stuff we never used after our big remodel and took it back to Lowe’s and Home Depot and got store credit, which I used to pick up the above items. So instead of paying Eastwood a couple C-notes, I got all this “not automotive Eastwood, but still ok in my book” spray stuff.
Then I went to Pep Boys and found some frame and rollbar paint. I splurged on a couple cans, although I could probably have just used the rubberized stuff. Pep Boys also had some high temp exhaust paint, so I got a can of that for the exhaust pipe/muffler. It was a bit less than Eastwood, and I didn’t have to wait for shipping.
The projectt will take two or three days. I have some “Honeydo” list to take care of tomorrow AM but in the afternoon, I’m going to spray rust killer and then bolt the rocker panel on the right side. That way if I mess it up, hopefully I’ll learn and not repeat the mistake when I do the left side, since that is the side I’ll be walking up to when I get in the Jeep to drive it. The second time I work on it I’ll be working the driver’s side rocker panel. The third time, I’ll spray the underside with the rust killer and then spray on the rubberized stuff, also the bottom part of the doors and the rocker panels. The final time, I’ll paint the exhaust with the special paint and paint the frame with the special frame paint.
That’s my project and the plan to carry it out. I am not restoring it. I am having a great time working on it, but it ain’t no restoration. Put it this way…the theme for the Beast for all cosmetics is “used or cheapest possible”, and get it better than it currently is. Mechanicals? I’ll have my shop do them. They do awesome work and will make sure that everything is done right. But for the stuff I can muddle through, well, where’s that rattlecan? I know I set it down here somewhere…
I’ll come back and report as I work through it, and will also try to post pictures. Wish me luck!
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Last edited by WWI Flying Ace : 08-21-2010 at 10:34 PM.
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Old 08-22-2010, 12:27 AM
Skeeter74 Skeeter74 is offline
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Good luck, sir. I am thinking of a cheap, spelled rattle can, repaint and spray can bed liner idea myself.
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  #3  
Old 08-25-2010, 01:56 PM
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WWI Flying Ace WWI Flying Ace is offline
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Update #1

I was getting ready to start the rocker panels and was looking at the extent of the rust. The panels are pretty bad…like, you can see to China through that hole bad, but the panels I have will take care of that. The Empire of the Rust...


Before I went to the carwash to get everything clean, I noticed my daughter had driven the Jeep last.


However, when I got to the car wash and pulled up the carpeting in front of the back seat to get the lay of the land, I saw the…tire.



Gaping holes in the floorboards. OK, so part of this project is to know when to fold ‘em too. The floorboards will have to be fixed. Dang…that is more than I can do I think. I'll start a thread asking for help on that one, but for now, back to our story. So, not wanting to waste the afternoon, I went to Plan B…the rust spray on the frame! First, get the Beast into the pod bay, Hal…and it fits (barely). You can see the white triangle of the AMC emblem I spray painted on the garage wall a couple weeks ago...



I spent an hour or so chipping at the rust underneath with an old grill brush (we needed a new one anyway)…then sprayed that stuff on…7 or 8 cans of the rust converter. Took a while but its all on. So, next time I am out there, I’ll spray the frame paint black and also the exhaust pipe and muffler with the special hi temp paint.

After that is done, I’ll have to get the floorboards fixed. Just not sure when that will be, unfortunately. But then I’ll use my patch panels for the rockers and the black on the bottom of the doors after the floor pan is fixed. No point in doing it sooner. Not quite what I wanted to do this weekend, but good to have something done!
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2007 Pontiac Solstice GXP
2001 Buick Century

“I never wonder to see men wicked, but I often wonder to see them not ashamed.”
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Last edited by WWI Flying Ace : 08-25-2010 at 02:30 PM.
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Old 08-25-2010, 03:56 PM
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ClovisMan ClovisMan is offline
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Man, thats A LOT of rust!!!! Probably be a good parts vehicle for one a little more solid. Does your frame look like swiss cheese too?
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Old 08-25-2010, 07:36 PM
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Coryd55 Coryd55 is offline
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Don't quit because of the rust.

Mine is/was just as bad - see my thread in my sig. It is coming along.

It is definitely worth it to see your progress if you decide to tackle it. Great feeling of accomplishment
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Old 08-25-2010, 09:25 PM
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Rich88 Rich88 is offline
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You really need a 3/8" drill with all manners and shapes of rotory wire brush attachments and decent eye goggles. Makes things go a lot faster and does a much better job than hand scraping.

Better yet is sand blasting, after shrouding the immediate area with clear plastic.

Best is a die grinder to just cut the cancerous panels out and rivet in repalacement metal after which you primer paint followed by undercoating.

Been there - done all that, and still a long ways to go.

Next is welding in replacement sections on rusted out frame work.
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  #7  
Old 08-26-2010, 07:39 PM
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WWI Flying Ace WWI Flying Ace is offline
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Quote:
Originally Posted by ClovisMan
Man, thats A LOT of rust!!!! Probably be a good parts vehicle for one a little more solid. Does your frame look like swiss cheese too?

Nah, frame's solid...just the floor pan and the rockers are bad.

Quote:
Originally Posted by Coryd55
Don't quit because of the rust.

Mine is/was just as bad - see my thread in my sig. It is coming along.

It is definitely worth it to see your progress if you decide to tackle it. Great feeling of accomplishment

That's the plan...got to fix the floor pan now before I can do the rockers, but I'll get there! I hope...will deffenitely be leaning on the forum for help though.

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1981 Jeep Wagoneer
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2007 Pontiac Solstice GXP
2001 Buick Century

“I never wonder to see men wicked, but I often wonder to see them not ashamed.”
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Old 02-21-2011, 03:52 PM
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WWI Flying Ace WWI Flying Ace is offline
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OK...finally got the floor pans done (http://www.ifsja.org/forums/vb/showthread.php?t=126905), and ready to put in the new interior, but waiting for the weather to improve (so the adhesive will work). Also, got the frame all painted, and the underside all rust killed and got the rubberized spray done on the whole undercarrisage/underneath. The past couple days I took advantage of the long weekend, and put on the passenger side rocker panel replacement! Then sealed it up, and sprayed in a can of that spray foam from home depot. I was looking at the driver's side, and it is in need of bondo but it is not bad enough to justify the installing of the driver's rocker panel replacement I have. So, I'll sell the replacement rocker panel that I got. I also sprayed a can of the spray foam in the driver's side. I'm sure the neighbors are scratching their heads about the foam coming out of the rocker panel, but I'll cut it off and then bondo it...next time I have a day off again and the weather cooperates, it will be bondo time. That will bring the rocker on the driver's side back, and then of course the fenders behind the wheels. And then, the black spray on the bottom of the doors/fenders will go on. Make no mistake, this is a chop job. If I paid someone for bodywork and they gave me back what I am doing, I'd be mad. But for me, doing it myself, I'm really having a good time and it is great to see things progressing! I love my Wagoneer. Thank you AMC! Thanks to everyone on the forum for your help and support!
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1981 Jeep Wagoneer
2007 Jeep Commander
1973 AMC Javelin AMX
2007 Pontiac Solstice GXP
2001 Buick Century

“I never wonder to see men wicked, but I often wonder to see them not ashamed.”
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Last edited by WWI Flying Ace : 12-25-2011 at 10:41 AM.
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  #9  
Old 02-21-2011, 04:31 PM
joe joe is offline
 
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Quote:
Originally Posted by WWI Flying Ace
It does need a new gas tank skid plate, but that is in the future.
Make a good judgement call on that. That's not really a skid plate that's the fuel tank mount that holds the whole thing up under the car.
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Old 02-21-2011, 05:06 PM
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Hmmm...thanks for the tip.

In that case maybe I'll move the skid plate up the list.
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2007 Pontiac Solstice GXP
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Old 03-06-2011, 12:45 PM
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WWI Flying Ace WWI Flying Ace is offline
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Decided to put on the driver's side rocker panel I had anyway, rather than sell it. I had it sitting there in the garage after all, and there will be enough bondo on this thing when I am done. May as well have some good metal parts too.
Got it on, sealed, and painted the undercoat of rust preventative on it yesterday, with just enough time for it all to dry before the rain came today. Man, you can really cut the hell out of your fingers when working with sheet metal! But it is great to be making progress, and making more room in the garage too with the parts actually on the car instead of just leaning against the wall! While I was underneath putting the seam sealant on, I got a nice slice in my forehead from a sharp edge sticking off the nuked gas tank skid plate. Looks like that will be next on the "parts to buy" list now. Thanks for the tip Joe...it is at the top of the list now that it has Ginsu-ed me! This weekend, the work I do on the Waggy will end with a nice tetanus shot at the minute clinic!
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1981 Jeep Wagoneer
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2007 Pontiac Solstice GXP
2001 Buick Century

“I never wonder to see men wicked, but I often wonder to see them not ashamed.”
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Old 03-06-2011, 12:56 PM
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mudhunter241 mudhunter241 is offline
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gets some cheap mechanic gloves and some safty glasses. Heavymetalthunder cut his finger down to the bone on his, and I somehow got a rust partical stuck in my eye. 5 trips later to the eye doctor he got it out. Im not tring to be a butthead just know form experience that its no fun and adds to the overall cost to the project!! haha!! we have a saying out by us you cut it and it cuts you
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Old 03-06-2011, 03:53 PM
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WWI Flying Ace WWI Flying Ace is offline
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Well said! I have been doing quite a bit of cutting so I guess it owed me one or two or three!

I had my safety glasses on and I have gloves but I didn't have them on, because I was "just trying to do this one last thing" before heading in when I got sliced. That is always how it goes...lesson learned! Down to the bone is mucho bad! Hope HeavyMetalThunder healed up ok.

Sorry to hear about your eye too! Did you get back to 100% after that got that chunk of metal out? That sounds horrible...my tetanus shot was pretty painless by comparrison.

Thanks for the advice, it is well taken. I'm learning as I go on this project and am glad to hear the war stories to learn from them too.
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1981 Jeep Wagoneer
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2007 Pontiac Solstice GXP
2001 Buick Century

“I never wonder to see men wicked, but I often wonder to see them not ashamed.”
-Jonathan Swift
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Old 03-06-2011, 07:06 PM
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Heavymetal thunder has 9 good working fingers after that, and I say I have a twinkle in my eye! Good news for me was it missed the pupil so yep 100%.
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Old 03-08-2011, 03:07 PM
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WWI Flying Ace WWI Flying Ace is offline
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Here's the "before" pic:


And here is the "after" pic:


Other side looks pretty much the same. The tetanus shot was worth it!
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1981 Jeep Wagoneer
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2001 Buick Century

“I never wonder to see men wicked, but I often wonder to see them not ashamed.”
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Old 12-22-2011, 02:58 PM
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OK, so there has been a lot that took place this fall! First, the Waggy won the first place trophy in the Jeep category of the AMCRC Nationals show in Annapolis this summer! It was the only AMC Jeep that showed (at the national show no less), so there was literally no competition. J Sometimes life is about showing up…
So, on to the current state of the Wagoneer…I got the sound deadening and the carpet kit put in all the way.




I also had an AMX steering wheel that I put on, I think it looks great!


Then, I added new window sweeps on the inside and outside of the doors, and on the tailgate window. I drove it around and it was SO MUCH QUIETER AND COOLER! All the sound deadening and insulation really cut down on the noise and heat in the interior, and the new window sweeps (especially the one on the tailgate glass) reduced the rattling by a ton! All the weekends and hours of work, and the expense, all came together. I was VERY happy…even proud of myself. But that was my mistake. In life, things are never that easy.
Unfortunately for me, I completed everything the same day that a hurricane came through our area. “Good thing I got the window sweeps replaced” I said to myself. Unfortunately, I didn’t notice that the new window sweeps somehow caused the driver’s and passenger’s windows to not go up all the way. There is about an 1/8 inch gap at the top of each. SO, needless to say, a fair amount of rainwater got inside the car on my nice fresh interior. It was only done for about 12 hours! Ah, the irony…
So, I had to tear the carpet back to get it cleaned up. All that work, for nothing. I have a band of duct tape at the top of both of the windows, inside and outside. It is keeping the interior dry, although it is definitely not the final fix. But it is good enough for now. I dried it out the carpet with those moisture reduction things from Home Depot, and with a carpet shampooer sucking up water, and with a hair dryer. In the end, I got it all dry, and then reapplied the sound deadening and carpet.


So now, that is all done, and it is looking great, but it is not perfect. But it is still better by far than when I got it, so I am still happy. There are still far fewer rattles but unfortunately, there is a fold in the carpet over the transmission tunnel that you can see in the picture, and there is a bulge in the driver’s floor from the grey felt sound deadening bunching up under there after it was torn back and dried out and reapplied. Those are my reminders that I had to re-do the interior after re-doing the interior.

Next steps will be to take back enough of the carpet to flatten out the bulge in the driver’s floor and reapply it. I will then install the running board trim that I got. And, obviously, I need to fix the windows. But it is making progress! Here is how she looks right now.


More to come when I make more progress…
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1981 Jeep Wagoneer
2007 Jeep Commander
1973 AMC Javelin AMX
2007 Pontiac Solstice GXP
2001 Buick Century

“I never wonder to see men wicked, but I often wonder to see them not ashamed.”
-Jonathan Swift

Last edited by WWI Flying Ace : 12-22-2011 at 03:14 PM.
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Old 12-22-2011, 09:14 PM
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Interior looks great! That AMX wheel does set it off...
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Old 12-25-2011, 10:36 AM
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Thanks! The wheel is a cool story...I got a bunch of interior parts for my AMX interior resto in a lot that included the wheel (which was one part I actually didn't need for that car). It was even brown, so matched the color of the FSJ. I was really happy that the AMC wheel fit the 8-model-years-newer-steering-column-from-a-"different"-manufacturer-FSJ without an adapter!
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1981 Jeep Wagoneer
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2007 Pontiac Solstice GXP
2001 Buick Century

“I never wonder to see men wicked, but I often wonder to see them not ashamed.”
-Jonathan Swift
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Old 12-25-2011, 02:28 PM
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Whose sound deadening did you use?
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Old 12-26-2011, 12:33 PM
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With all of that fancy sound deadening and the spray foam in the rocker panels, how much more work do you reckon you'd have to do to make 'er float? Combining two of my favorite things in all the world, fishing and FSJs, would be... well, I'd end up divorced for sure.

But seriously though, it's really looking great. Good job! Guys like you inspire me to tackle my interior one day.
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