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Renegade 1

Discussion in 'Builds and Fabricators Forum' started by montanacj, Aug 6, 2016.

  1. Sep 5, 2018
    sterlclan

    sterlclan Member 2022 Sponsor

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    use as much of the new rocker as you can. I always go at least two inches beyond the visible rust.
     
  2. Sep 6, 2018
    montanacj

    montanacj Member

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    Tonight I worked on the getting to the cowl support. I started by removing the rusted on rocker trim piece.
    [​IMG]

    Ground off the screws I wasn’t even going to attempt to remove those things. That rocker trim piece was rusted to the floor.

    [​IMG]


    The cowl support is rusted bad
    [​IMG]


    It took some time to inch my way up to clean metal

    [​IMG]

    But eventually I found some rust free cowl support.

    [​IMG]
     
    Last edited: Sep 6, 2018
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  3. Sep 8, 2018
    montanacj

    montanacj Member

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    Working on the passenger side, made some good progress. First up the floor had to come out.

    [​IMG]

    Next up was to work my way along the rear floor support and drill out the spot welds and peel up the remaining floor.

    Making progress

    [​IMG]

    And it’s off

    [​IMG]
     
  4. Sep 8, 2018
    montanacj

    montanacj Member

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    Now time to work on the edge where the rocker meets up with rear floor support, a delicate area to be drilling and sanding on.

    [​IMG]

    [​IMG]

    The good news is after all that the test fit of the rocker panel and floor all looks squarish
    [​IMG]
     
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  5. Sep 8, 2018
    sterlclan

    sterlclan Member 2022 Sponsor

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    ish is right, the factory was + or- 1/2 inch for a tolerance...
     
  6. Sep 9, 2018
    montanacj

    montanacj Member

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    Didn’t have much time but did manage to get the cowl support close to fitting. I was concerned the curve on my new piece wouldn’t match the curve on the remaining cowl support but it appears to be fitting. My next move is to finish fitting the cowl support and then test fit that with the floor pan and rocker to see how all that’s coming together before I weld anything up.
    [​IMG]

    Did manage to get in a nice hike today with my wife and dog up to the peak in the background of this photo. Trapper peak elevation 10157’

    [​IMG]
     
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  7. Sep 10, 2018
    montanacj

    montanacj Member

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    Worked on fine tuning the cowl support repair piece making sure it’s square and lines up well. Then I test fitted the floor pan and it looks good. Thankfully everything is lining up
    :beer:

    [​IMG]
     
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  8. Sep 10, 2018
    montanacj

    montanacj Member

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    Another angle.
    [​IMG]
     
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  9. Sep 13, 2018
    montanacj

    montanacj Member

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    Very little time this week but I did manage to make some coupons out of the extra 14 gauge cowl support piece to practice welding this material. I’m a beginner welder, did some welding in high school but that’s about it.

    Anyhow, thought it would be a good idea to practice before I weld the cowl support piece. I’ve toyed with laying a bead vs stitch welding the 14 gauge. I’m getting good penetration either way but better if I lay a short bead. Just don’t want to cause any warping.

    Feel free to give advice or critique the welds.

    Here is my version of a stitch weld
    [​IMG]

    Here is a bead not my best work had some blow through And the fitup isn’t that great but you get the idea.

    [​IMG]



    Back side of the stitch weld on the right and a bead on the left
    [​IMG]
     
    Last edited: Sep 13, 2018
  10. Sep 13, 2018
    montanacj

    montanacj Member

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    At this point I’m leaning toward stitch welding to mitigate heat and blow through. Although the beads giving me better penetration.

    Again it’s 14 gauge and this piece is the cowl support. Feel free to shoot holes in my plan or give advice.

    I will add I have been practicing this weld like it would be in the Jeep thus I’m welding the inside of the cowl support.
     
  11. Sep 13, 2018
    montanacj

    montanacj Member

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    Here is a coupon I did a while ago after grinding. However at this point I was welding outside of the cowl support which won’t be possible in situ

    [​IMG]
     
  12. Sep 13, 2018
    sterlclan

    sterlclan Member 2022 Sponsor

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    i do spot welds and let them cool before welding more. skipping around and allowing the steel to cool helps with warpage.
     
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  13. Sep 14, 2018
    Keys5a

    Keys5a Sponsor

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    14 ga is pretty heavy, so warpage should be minimal. Just don't run a continuous 5"-6" bead.
    The last photo looks like you are getting the hang of it!
    -Donny
     
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  14. Sep 14, 2018
    montanacj

    montanacj Member

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    ^^Agreed, I was calling it stitch welding but basically one to three welds and then move elsewhere. The 14 gauge is pretty robust and is only blowing through near edges or a corner.
     
  15. Sep 21, 2018
    montanacj

    montanacj Member

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    Got the cowl support welded in and fit up with the floor. Everything came together nice.

    [​IMG]

    [​IMG]

    [​IMG]
     
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  16. Sep 23, 2018
    montanacj

    montanacj Member

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    Next up was fitting the rocker panel, this required some precise surgery near the front of the rocker and firewall.

    Here it was to start
    [​IMG]

    Got the panel off Without hurting underlying firewall/floorboard steel

    [​IMG]
     
  17. Sep 23, 2018
    montanacj

    montanacj Member

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    Made the cut with an angle Grinder, it turned out ok, it’s like doing surgery with a chainsaw. It’s straighter then it looks in this photo.

    Halfway through the cut, I’m sure there are better tools for this but some patience and a thin cut off wheel and bobs your uncle

    [​IMG]
     
    Last edited: Sep 23, 2018
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  18. Sep 23, 2018
    montanacj

    montanacj Member

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    And it’s off, I then proceeded to play with fitment and get it lined up. Those little butt welding clamps from harbor freight help tremendously with the panels being flush with each other.

    [​IMG]

    The good news is everything is once again squarish and the cowl support lines right up so bonus. :p

    I will say the whole things like a Rubics cube with multiple panels all meeting, it’s a measure 5 times cut once situation
     
    Last edited: Sep 23, 2018
  19. Sep 23, 2018
    montanacj

    montanacj Member

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    Next up is fitting the floor pan and making that cut where the floor board comes off the fire wall. It’s a slow methodical deal but it’s fun
     
  20. Sep 23, 2018
    montanacj

    montanacj Member

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    Did manage to get the floor cut and test fit today, a little more massaging and it’s gonna be lined up.

    [​IMG]

    [​IMG]
     
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