Post by dan on Feb 13, 2014 8:22:02 GMT -4
Since I don't have enough on my plate already, with having to build a completely new house out of an existing one (long story), the Wife decided she wanted the XJ from down the road. the price was decent, and the underside was in good condition, so I couldn't turn it down..
I never got any photos of it before it went inside,or before I started ripping and cutting, but I'll start now.
'98 XJ sport, it has 340xxx km on it. floors are in really good shape, only a few small holes. rockers had been replaced a year or two ago, but by a hack mechanic, inner panels were hacked off almost flush with the floor, and "new inners" were bent up and riveted on with 3-4 rivets per side. They didn't look too bad at a glance, but Steph wants to have herself a light wheeler, and something she can drive to Acadia with if the weather isn't fit for the Golf.
I cut the rockers out flush with the top lip that the plastic step sits on, since everyrhing below that was half-ass replacement. I used 2x2 1/8" square tube as an insert to fill the void some, and make a more factory-looking drop from the sheet metal.
Since the inner rocker panel was all hacked up and missing, I made an "L" shaped piece of sheet metal, ran it along to use as a lip for the 2x6 to sit on, and to weld it to, you will see it in the underside photo in a minute.
the 2x6 3/16" was used for the main body, tapered the ends, and welded them closed.
Still have lots of sheet metal work to do yet..
driver side rear wheelwell
back panel
This is what the replacement rockers looked like.
and the reason why I said yes to buying this one.
anyways, I have 5 or 6 hours on it so far, sheet metal work is gonna really slow me down, but I'll be picking away at it when I can.
I never got any photos of it before it went inside,or before I started ripping and cutting, but I'll start now.
'98 XJ sport, it has 340xxx km on it. floors are in really good shape, only a few small holes. rockers had been replaced a year or two ago, but by a hack mechanic, inner panels were hacked off almost flush with the floor, and "new inners" were bent up and riveted on with 3-4 rivets per side. They didn't look too bad at a glance, but Steph wants to have herself a light wheeler, and something she can drive to Acadia with if the weather isn't fit for the Golf.
I cut the rockers out flush with the top lip that the plastic step sits on, since everyrhing below that was half-ass replacement. I used 2x2 1/8" square tube as an insert to fill the void some, and make a more factory-looking drop from the sheet metal.
Since the inner rocker panel was all hacked up and missing, I made an "L" shaped piece of sheet metal, ran it along to use as a lip for the 2x6 to sit on, and to weld it to, you will see it in the underside photo in a minute.
the 2x6 3/16" was used for the main body, tapered the ends, and welded them closed.
Still have lots of sheet metal work to do yet..
driver side rear wheelwell
back panel
This is what the replacement rockers looked like.
and the reason why I said yes to buying this one.
anyways, I have 5 or 6 hours on it so far, sheet metal work is gonna really slow me down, but I'll be picking away at it when I can.
I use the generic white dust masks with the metal strip over the nose. They stop most of the dust, sometimes just get a bit around the bridge of the nose. I never even thought about a welding specific respirator, will have to source one up. If you don't mind, where did you get yours and how much $$$? 
