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Frankenstein Wagoneer

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Category: Competition
Forum Name: Jeeps and Eagle 4x4 fun.
Forum Description: Rock crawling events or results, Muddin' it through the riverbed with your Eagle
URL: https://theamcforum.com/forum/forum_posts.asp?TID=22111
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Topic: Frankenstein Wagoneer
Posted By: WWI Flying Ace
Subject: Frankenstein Wagoneer
Date Posted: Aug/21/2010 at 11:24pm

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!



-------------
1973 Javelin AMX

2007 Jeep Commander

"Be kind, for everyone you meet is fighting a great battle."

-Plato



Replies:
Posted By: PlazinJavelin
Date Posted: Aug/22/2010 at 9:28am
Sounds like a cool project. Good luck and post those pics. I was just at the local pullapart yesterday looking over a Wagoneer and Grand Wagoneer. Both from '88 and in fair shape. Still mostly complete but with some bit's and peices missing now. Shame to see them go. I'm thinking about going back to grab a few more bit's that might fit my Jav project.

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PlazinJavelin
Marlin Wannabe




Posted By: WWI Flying Ace
Date Posted: Aug/25/2010 at 3:04pm

Here is the unsuspecting girl now...

 

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 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 barely see the red triangle of the AMC emblem I painted on the garage wall a couple weekends 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!   

 



-------------
1973 Javelin AMX

2007 Jeep Commander

"Be kind, for everyone you meet is fighting a great battle."

-Plato


Posted By: WWI Flying Ace
Date Posted: Sep/08/2010 at 12:38am
Progress report!

OK, so I had some serious time with the Beast this past weekend. Honey Do list was pretty big, but managed to do a lot of grinding away of rust, and chopping out of rust. Here is the “during”…Dremmel grinding fury! And tin snips…




Rust be gone…there is the left rear door sill, and my foot, and my gloves, and my driveway…



The epoxy I was able to luck into was from aerospace, and would have been great…but it was old and expired. So, I went to the auto parts store and got JB Weld…that and the pop rivets got the plates on in the back. Here is the “after”, for the right rear quarter panel:



My problem is that once I got the carpet out, it became apparent that the seat belt mount is rusty, as are a couple of the seat mounts. Now, I am having a great time messing around with the patches for the floor pan, but a seat belt and the seat mounts are safety concerns. So, I’m going to take it up to my guy for him to do the professional weld it like a Sherman tank fix on the brackets and the seat mounts. Everything else…I’ll keep messing around with. I need to get the front done and I have the patch panels ready to go, but I don’t know how big they will need to go for the seatbelts and the seat mounts so I am on hold for the moment. Hope to have it back later in the week so I can work on it this weekend and hopefully get the floor pans all done…and then I can finally do the rockers as originally planned!

-------------
1973 Javelin AMX

2007 Jeep Commander

"Be kind, for everyone you meet is fighting a great battle."

-Plato


Posted By: Freecat1
Date Posted: Sep/08/2010 at 2:22pm
Hey Ace    Can I use the first picture for my Wagon & Wagoneer calendar project?  I will make you one at cost if I use it?  Freecat1


Posted By: WWI Flying Ace
Date Posted: Sep/08/2010 at 2:25pm
You bet! That would be great!  The Beast would be honored to be a part of the calendar. 
 
When do you need the pics...if I get done with the planned repairs it will look better and I might have a better picture...unless of course you are going for the rugged rusted look.  Smile


-------------
1973 Javelin AMX

2007 Jeep Commander

"Be kind, for everyone you meet is fighting a great battle."

-Plato


Posted By: Freecat1
Date Posted: Sep/08/2010 at 2:30pm
The look is perfect>>  Thanks.  Only need 5 more>>>>>>>Clap


Posted By: WWI Flying Ace
Date Posted: Oct/21/2010 at 1:12pm
OK, been a while because of family stuff but the next stage is nearly here...got the old metal cut out and the aluminum patches done on the driver's side, left rear, right rear, with pop rivets, epoxy, rust killer.  Got the rust cut out and the rust killer on the passenger's side, but need to do the patch and the epoxy and the pop rivets.  Getting pretty good at it now, should be about 30 mins (give or take) to get the last patch in and riveted!
 
Ordered the seam sealer from carparts.com (same stuff as JC Whitney but cheaper), when that gets here I'll seal it all, then order the carpet kit and install! 
 
WHile I wait, I will begin on the rocker panel replacement that started this whole thing.  I should have time this weekend, since I mowed the lawn for the last time last weekend.  Making progress!


-------------
1973 Javelin AMX

2007 Jeep Commander

"Be kind, for everyone you meet is fighting a great battle."

-Plato


Posted By: farna
Date Posted: Oct/31/2010 at 12:12pm
You could fiberglass the floors. That's what I'm going to do to the floor in my J-10 project truck. Of course the seat and seatbelt mounts aren't rusted, just the main floor areas. Even so, I'd probably just screw a piece of steel across the bottom of the floor anchored into good metal and drill through that for the mounts, then fiberglass over the floor. A swiss cheese floor can be 'glassed over as long as the holes aren't too big (nickle size or smaller). If you have an area with bigger holes a piece of stiff wire screen over them works. Window screen will work, but I prefer the stiffer "hardware cloth" or some kind of metal mesh that the resin will flow through and bond in. Fiberglass doesn't rust! The metal CAN rust around it, so make sure you clean and paint the metal before 'glassing over. I undercoat the bottom side good. If no oxygen or moisture can get to the metal it will stop rusting.

You can use paintable caulk for seam sealer. Think about it -- it lasts outside in the weather for 10-20 years, has to last longer protected in a car! I had some big gaps to fill in my trailer project and used paintable caulk with fiberglass mesh drywall tape for reinforcing. Sealed everything up nicely! See http://theamcforum.com/forum/rambler-trunk-trailer_topic20151_page2.html, scroll down near bottom of page.


-------------
Frank Swygert


Posted By: WWI Flying Ace
Date Posted: Nov/01/2010 at 10:10am

Hi Farna-

I love the trailer project!  I actually just completed the aluminum patch panels this weekend, and then I had ordered some sealant a couple weeks ago which got in this week.  So, this weekend I actually got the patches done and the sealant!  Woo hoo!
Driver's side (the grey is the brush on sealant from Carparts.com over the aluminum plates that I installed.  The black is the rust killer spray.)
 
Here is the Passenger side:
 
Here is the left rear floorpan and the front corner of the rear wheel well:
 
Here is the right rear passenger floorpan and the front of the rear wheel well:
 
Here is the right rear wheel well patch in the bed.  The left wheel well is similar.
 
Next step will be to get the heat/sound insulation installed, then the carpet goes back in!  I ordered decent scuff plates and kick plates from a guy too for cheap. 
 
After all this, I'll eventually be able to get back to the rocker panels!  I did test fit the replacements I have but they will need to be slightly modified to fit in the back as the wheel wells were cut out for the bigger tires.  Ah, so fun and yet so much work!  :)  I'll keep the forum posted as I make progress...
 


-------------
1973 Javelin AMX

2007 Jeep Commander

"Be kind, for everyone you meet is fighting a great battle."

-Plato


Posted By: WWI Flying Ace
Date Posted: Mar/06/2011 at 4:10pm
I have had all the sound insulation and a new carpet kit ready to go in the interior since last fall, but I have to wait for the weather to improve before I can put it in (the spray adhesive won't work if it is too cold). So I've been working on the rocker panels instead.
 
Finally got the patch rocker panels put on. Got stamped parts sent out from JC Whitney or Carparts.com or whatever for about $45 each. They install over the old ones. They are cheap parts, but I can't see spending a lot of coin on the Waggy, as I plan to abuse it when it is all done and the NOS rockers I tracked down were $300, which was about 15% of what I paid for the whole vehicle. It just didn't make sense. The stamped parts will work just fine for my hack job and I'm having fun working on it.

I sanded and cut and sprayed out and neutralized all the rust on the old rockers with the rust-killer stuff. Then I sprayed the insulation foam from Home Depot inside the rocker panel, and let it expand to act as sound deadener, and to prevent water getting in. After that all dried and squished out the holes, I sliced it off at the level of the body, and then I attached the new rocker panels with JB Weld and lots of rivets. After they were installed, I then sealed them. I sliced the heck out of my fingers when cutting the metal but got them on the rig. Then sealed them, and sprayed the whole thing with the rust preventative. Got all that wrapped up yesterday (finally). There is more room in the garage now that the rocker panels are actually on the vehicle instead of leaning on the wall!

I also managed to Bondo the right rear fender behind the wheel. There is a good volume of Bondo that will go there, and on a couple of the other fenders, which will be the next stage of the body work. Bondo does not work for full restoration, but this Waggy is not really getting restored, so Bondo will be used. Plus that way I learn how to use Bondo (never used it before). And I got to buy an orbital sander. Always happy to buy a new power tool...

I also cut my forehead on a jagged piece of metal that is hanging off the nuked gas tank skid plate, so I get to complete the weekend automotive repair activities by going to the MinuteClinic and getting a tetanus shot! Oh, what fun! But it is worth it...the old girl is really starting to look better, and I'm really enjoying the time spent working on it. If I paid anyone to fix it and got the quality of work I am doing on it, I'd be mad. But since it is my science project, I'm having a lot of fun with it!  Just got back from my tetanus shot...don't have to worry about that for 10 years now!  Even I am getting improved by the Wagoneer build project!  :)


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1973 Javelin AMX

2007 Jeep Commander

"Be kind, for everyone you meet is fighting a great battle."

-Plato


Posted By: farna
Date Posted: Mar/06/2011 at 5:44pm
I had priced some of that brush on sealant, but decided to use a good paintable latex/silicone caulk instead. Heck, it lasts 20+ years in the weather, got to least as long or longer in a car! 

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Frank Swygert


Posted By: WWI Flying Ace
Date Posted: Mar/06/2011 at 6:19pm
That is a good idea.  I have repurposed a lot of Home Depot stuff for the Waggy but I already had the sealer (got it last summer) so I figured I'd just use it instead.  But if I had it to do again, the caulk you are talking about would be perfect, I'd think. 

-------------
1973 Javelin AMX

2007 Jeep Commander

"Be kind, for everyone you meet is fighting a great battle."

-Plato


Posted By: WWI Flying Ace
Date Posted: Mar/08/2011 at 3:21pm

"Before" picture:

"After" picture:



-------------
1973 Javelin AMX

2007 Jeep Commander

"Be kind, for everyone you meet is fighting a great battle."

-Plato


Posted By: nossliw
Date Posted: Jul/18/2011 at 10:50pm
WELL DONE!


Posted By: carnuck
Date Posted: Aug/07/2011 at 9:46am
In case you didn't know, http://bjsoffroad.com and http://zmjeeps.com have the best collection of FSJ parts

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Got an Eagle?
http://forums.amceaglesden.com" rel="nofollow - http://forums.amceaglesden.com


Posted By: WWI Flying Ace
Date Posted: Aug/10/2011 at 9:59am
Thanks!  I knew about BJs (got the interior kit there that I'll be installing on my week off soon).  But had never heard of ZM Jeeps.  Thanks for the tip!
 
I will be updating after my next step (the interior work) which should take place this month (assuming I can get the days off). 
 
 
Originally posted by farna farna wrote:

I had priced some of that brush on sealant, but decided to use a good paintable latex/silicone caulk instead. Heck, it lasts 20+ years in the weather, got to least as long or longer in a car! 
 
Farma, I'll be using your idea after all.  I got that sealer that was special for cars but it has cracked as the vehicle flex stressed it.  So I'll be doing the silicone caulk thing over the top and see if that works better!  Got to keep all the water out before I get the new carpet kit put in.
 


-------------
1973 Javelin AMX

2007 Jeep Commander

"Be kind, for everyone you meet is fighting a great battle."

-Plato


Posted By: WWI Flying Ace
Date Posted: Dec/22/2011 at 2:52pm

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 above!  As you can see in the last posting, 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…    


-------------
1973 Javelin AMX

2007 Jeep Commander

"Be kind, for everyone you meet is fighting a great battle."

-Plato


Posted By: farna
Date Posted: Dec/22/2011 at 3:56pm
Great job so far! The "AMX" wheel was an option on Wagoneers, at least some years. Sold as a "sport" steering wheel. May have just been on Cherokees and J-trucks like the Honcho, not sure, just know it was available on some. 

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Frank Swygert


Posted By: 73ambcoupe
Date Posted: Dec/22/2011 at 7:40pm
Cool project!

When I was researching rockers for mine I ran across the "Good-mark" site. I couldn't believe they still made original rockers, but if the ones you used worked great. I never bought mine from Good-mark, but went to home Depot and bought some 16 gauge metal and formed them myself. Rust is strange because my inner rockers were perfect and the outer rockers had rust. I cut out the bad metal, riveted the new ones I made on and all is good. I painted them flat black and until I win the lottery these improvements will serve me well!



 



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Posted By: jeepjerry
Date Posted: Dec/22/2011 at 9:43pm
Lookin' sweet, Ace!!

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-72 SST Javelin -under restoration. Alfano Performance 360.

-76 CJ-5,strong 360, 6" lift, 35"s.

-77 J-20, 4bbl 360/t-18, 33"s.

marlinsteve's son





Posted By: Gonzobongo
Date Posted: Dec/03/2012 at 9:02pm
I just recently "started" an effort to bring a decrepit 83 Wagoneer limited back to life. First time ever doing any of this stuff. No engine work experience, no body work experience, and just a touch of interior work in the past. I've researched so much in an effort to not screw it up. Every other Waggy project I read about people lamenting about the speck of rust on their jeep from Arizona, Nevada, ect... I really got discouraged before I really got started. But this one of yours, man, it's an inspiration to me! My Swagoneer is a serious bit of work. But your efforts really got me jacked up to get working on it! Thank you.

Now, any advise on how to convince the wife to get on board now? :)


Posted By: WWI Flying Ace
Date Posted: Dec/05/2012 at 1:29pm

Glad to hear that the Waggy is an inspiration!  Good luck with yours!  I am sure there are more “correct” ways to go about it but as you gathered I am a first timer.  Best thing I can say is, have a plan but expect to deal with major things that you didn’t or couldn’t foresee until you stumbled across them.  Also, there is a lot of good information here, and great people willing to help with their knowledge.  Also, there is a lot of Wagoneer specific good information at the IFSJ site.  http://www.ifsja.org/" rel="nofollow - http://www.ifsja.org/

As for convincing the wife…buy her presents…lots and lots of presents!  Although not enough to cut in too much to the parts you will need for the Wagoneer!  J  Good luck with the project, and keep us posted!       



-------------
1973 Javelin AMX

2007 Jeep Commander

"Be kind, for everyone you meet is fighting a great battle."

-Plato


Posted By: CAPTSmith
Date Posted: Oct/21/2013 at 12:31pm
How is that Frankenstein Waggie doing these days!  Smile


Posted By: WWI Flying Ace
Date Posted: Oct/31/2013 at 11:02am
Unfortunately for me but fortunately for someone else, she's up for sale.  I've changed jobs and don't have a choice.  :(

http://theamcforum.com/forum/topic55140_post494028.html#494028" rel="nofollow - http://theamcforum.com/forum/topic55140_post494028.html#494028

I love her a lot...someone will be getting one heck of a great Jeep!


-------------
1973 Javelin AMX

2007 Jeep Commander

"Be kind, for everyone you meet is fighting a great battle."

-Plato


Posted By: CecileG
Date Posted: Dec/29/2016 at 4:39am
I have watched a lot of films and read the book of Mary Shelly, http://bigpaperr.com/blog/frankenstein-critical-essay - http://bigpaperwriter.com/blog/frankenstein-critical-essay has some more facts about Frankenstein!



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