I am new to 
. Have 97 xj 4 door sport. 7 years ago, upon removing rear flares and bumper, found PO had allowed significant rust to eat away back end lower portion of both rear quarter panels. Back then I did the Cut-N-Fold. Fabricated a sheet metal box to fit the hole created after cutting out all the rust. Fastened the metal box using a combination of existing cleaned up metal, MIG spot welds, and 3M structural adhesive. Box edge that contacts the wheel house was fabricated longer to lay over the inside of that portion of the Wheelhouse. Wire brushed inside of wheel house area, used 3M adhesive, in conjunction with pop rivets to pull the two panels together tight for curing. Left pop rivets installed, covered with adhesive under the wheelwell. Still sealed after 7 years.
At the time, my top priority was replacing the rockers. Used the 2x6 structural tubing idea found elsewhere. Totally sealed, stitch welded and plug welded into place. Turned out great. Patched the dog legs on each side. Did rust mitigation on the rear wheel arches.
But now I need to deal with the Rear Wheel Arch Rust and Re-do the dog legs. Its reached the pinch weld line at the top of each arch. I bought new rear quarter replacement panels. Now what?
1. Replace the whole Quarter Panel - both sides (this would take the jeep out of service for a while)
2. Replace only the portion of Quarter Panel compromised by rust (just the arch and dog leg)
(would take jeep out of service long enough to cut out just the rust and fasten in the repair piece)
Comment: I read elsewhere where a poster created NUT STRIPS to facilitate attaching the Side Armor. I liked that idea.
But which option is better?
Doing option 2, I still have to prep, rust proof, and replaced metal. But if I plan on installing SIDE ARMOR, do I really need to finish the panel rust repair painting? I saw that Rusty's and or Rough Country Armor comes pre-finished whereas Dirtbound Offroad Armor comes bare metal.
Do I really need the Armor? I am not a heavy duty offroader. The only obstacles I might come in contact with are trail rocks and stumps in clear cuts. But after wasting time fooling around with the OEM rear flare mount design, I really like the idea of steel Flares. I also like the additional strength the Side Armor would provide. My thinking at this point is that I wouldn't have to cover the rear portion of the jeep with plastic to protect it against rust, metal grinding dust and paint over spray, to do the whole job all at once which would take more time. I would only need to take the jeep out of service long enough to cut the arch rust out, and then fix the hole with the new pre-cut repair pieces cut from the whole new QP.
In doing this repair, is there a Unibody integrity issue to consider by only replacing the arch portion of the quarter panel?
. Have 97 xj 4 door sport. 7 years ago, upon removing rear flares and bumper, found PO had allowed significant rust to eat away back end lower portion of both rear quarter panels. Back then I did the Cut-N-Fold. Fabricated a sheet metal box to fit the hole created after cutting out all the rust. Fastened the metal box using a combination of existing cleaned up metal, MIG spot welds, and 3M structural adhesive. Box edge that contacts the wheel house was fabricated longer to lay over the inside of that portion of the Wheelhouse. Wire brushed inside of wheel house area, used 3M adhesive, in conjunction with pop rivets to pull the two panels together tight for curing. Left pop rivets installed, covered with adhesive under the wheelwell. Still sealed after 7 years. At the time, my top priority was replacing the rockers. Used the 2x6 structural tubing idea found elsewhere. Totally sealed, stitch welded and plug welded into place. Turned out great. Patched the dog legs on each side. Did rust mitigation on the rear wheel arches.
But now I need to deal with the Rear Wheel Arch Rust and Re-do the dog legs. Its reached the pinch weld line at the top of each arch. I bought new rear quarter replacement panels. Now what?
1. Replace the whole Quarter Panel - both sides (this would take the jeep out of service for a while)
2. Replace only the portion of Quarter Panel compromised by rust (just the arch and dog leg)
(would take jeep out of service long enough to cut out just the rust and fasten in the repair piece)
Comment: I read elsewhere where a
poster created NUT STRIPS to facilitate attaching the Side Armor. I liked that idea.But which option is better?
Doing option 2, I still have to prep, rust proof, and replaced metal. But if I plan on installing SIDE ARMOR, do I really need to finish the panel rust repair painting? I saw that Rusty's and or Rough Country Armor comes pre-finished whereas Dirtbound Offroad Armor comes bare metal.
Do I really need the Armor? I am not a heavy duty offroader. The only obstacles I might come in contact with are trail rocks and stumps in clear cuts. But after wasting time fooling around with the OEM rear flare mount design, I really like the idea of steel Flares. I also like the additional strength the Side Armor would provide. My thinking at this point is that I wouldn't have to cover the rear portion of the jeep with plastic to protect it against rust, metal grinding dust and paint over spray, to do the whole job all at once which would take more time. I would only need to take the jeep out of service long enough to cut the arch rust out, and then fix the hole with the new pre-cut repair pieces cut from the whole new QP.
In doing this repair, is there a Unibody integrity issue to consider by only replacing the arch portion of the quarter panel?
