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Rust repair on the Comanche

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hassyfoto View Drop Down
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    Posted: Aug/26/2016 at 10:03pm
Well is started last week. I found the typical east coast rust above the wheel wells on the bed of the Comanche. Went to a local pick your own junkyard & bought two Cherokee fenders. I cut the fender wheel opening off the fenders to use on the bedside of the Comanche. It actually worked fairly well once you figured out that you had to cut the fender patch twice in order to work on the bedside.

I will post some pics once I upload from my phone.
Murphy's Law:
Any given mechanical job you decide to solve alone will imminently require a third hand, at its most critical moment

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mixed up View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote mixed up Quote  Post ReplyReply Direct Link To This Post Posted: Aug/30/2016 at 3:37am

 the trick is to over lay the panel on the other panel then cut with a cut off wheel through both panel so the line match up then you can butt weld them in place good luck on the project i alway love the tough look of those jeeps

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hassyfoto View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote hassyfoto Quote  Post ReplyReply Direct Link To This Post Posted: Oct/28/2016 at 7:09am
Comanche rust repair update. 
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Cut out the rust, and although I did not get any pics, I cut out the rust of the inner fender first, installed a replacement metal patch, epoxy primed and painted the patch on both sides. I left the flange area bare metal and sprayed weld-thru primer on that area. Once both fender well and bedside were welded up, I came back on the inside of the weld repair with rust-proofing material. 

 I used a cherokee fender for my patch panel for the bedside. The bedside is wider between the center contours then the on the fender, so, although the patch works very well, I did need to split the fender metal patch, align the metal patches and create a third metal strip in between the metal patches from the fender. 



Edited by hassyfoto - Oct/28/2016 at 7:18am
Murphy's Law:
Any given mechanical job you decide to solve alone will imminently require a third hand, at its most critical moment

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hassyfoto View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote hassyfoto Quote  Post ReplyReply Direct Link To This Post Posted: Nov/01/2016 at 7:13am
The Rocker panels are installed.  Cut out the old rusted panels right at the factory spot welds. I sanded primered and painted the back side of the replacement panels for future rust protection. I taped off the back side of the flange area and after painting the backside of the panels the 1/2 of bare metal showing was painted with weld-thru primer ( Zinc rich primer) 

Before installing the rocker panels, I cut out the rust on the inner rocker panels and made a few metal patches, welded in place and applied primer, paint and weld-thru primer the same as the outer rocker panel. 

Unfortunately the replacement rocker panels were not made correctly (contours were not correct) and I had to split the rocker panel length wise, and create the correct contour.

Finished cleaning the welds, body work and epoxy sealer to finish up the weekend.



Murphy's Law:
Any given mechanical job you decide to solve alone will imminently require a third hand, at its most critical moment

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raysinvegas View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote raysinvegas Quote  Post ReplyReply Direct Link To This Post Posted: Nov/01/2016 at 7:55am
Nice work!
Andy Ray
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