The Wrangler's fuel tank and...
The Wrangler's fuel tank and rear bumper were removed and the whole area was sandblasted clean. This is typical damage done by the harsh winters, moisture, and road salt found in and around the greater northern rust belt. Both rear framerails were toast. Damage extended into the rear crossmember and body mounts as well.
Rust is that four letter word that strikes fear into the heart of any vehicle owner. Just thethought of that scaly cancer forming on the flanks of your favorite ride is enough to send most owners into a self-induced cardiac arrest. And for years, many have sought out ways to protect their favorite vehicle from the onslaught of this parasite, often spending insane amounts of cash on coatings and other products just to fend off the beginnings of something that will eventually catch up with most daily-driven vehicles.
You pick up a good amount of dirt under the Jeep and in your framework. Add some moisture and winter road salt, and presto, you have a corrosive batter that will go to work on your chassis, slowly degrading it over time. Then add in high humidity and there's not much you can do once that protective barrier is broken. When looking for a used Jeep to build up in the northeast, the first question is never: "How does it run?" It's more like, "Is the frame Swiss cheese?" or "How much pavement can I see through the floor when I'm driving it?"
Luckily for us, there are companies like Auto Rust Technicians to help us do battle with these issues. Based in Cranston, Rhode Island, in the heart of the northeast rust belt, these metal masters have been taking care of New England's drivers for over 30 years. Not only by cutting and welding cancer-stricken rides, but also by developing new sheetmetal products to help the do-it-yourselfer repair badly damaged frames and subframes. Auto Rust Technicians offers Safe-T-Cap frame reinforcement plates for several different Jeep applications, as well as other makes. Here's how Auto Rust shop foreman Mike Alba installs the Safe-T-Caps on the rear of a rusty '87-'95 Wrangler.
Alba trimmed out the damaged...
Alba trimmed out the damaged framerails with a plasma cutter, making sure to keep as much useable frame as possible to attach the frame cap. Notice that much of the bottom of the rail was bad. This is usually due to the standing water, dirt, and salt trapped inside.
The Safe-T-Cap kits are cut...
The Safe-T-Cap kits are cut out with a CNC plasma cutter and welded up in the shop, ensuring a correct fit. They are built out of 11-gauge steel, which is a little thicker and stronger than the stock frame material. Alba test fit the cap, sliding it over the original framerail. It needed a little trimming for proper fit. This process was repeated on the passenger side and measurements were taken to make sure they matched up correctly in length. After this, the rear crossmember was mocked up in place.
Alba took a few measurements...
Alba took a few measurements of the corroded body mount area and then built a replacement out of 14-gauge steel. After the plug section was in place, Alba put the framerails and crossmember back in place to locate where to drill the bolt holes for the body mounts. After drilling out the body mount hole, Alba welded a washer and nut on the back of the body mount plug panel for the body mount bolt. The same was done on the passenger side.
After reattaching the framerail...
After reattaching the framerail cap and crossmember, a body bushing was inserted and bolted up. The body mount plug panel got another dose of the MIG welder and everything was cinched together. The same procedure is repeated on the passenger side. From the rear, the crossmember looks bone stock. Like the Safe-T-Caps, it's also made in-house out of 11-gauge steel. With the crossmember aligned properly, the frame cap was ready for final welding. All of the edges of the cap get a thorough weld bead placed on them.
After double-checking fitment,...
After double-checking fitment, Alba laid fresh weld beads along every accessible edge of the Safe-T-Caps and rear crossmember, giving a good strong bond.
The leaf-spring shackles were...
The leaf-spring shackles were installed using their original hardware. The fuel tank, rear bumper, and custom hitch were reinstalled as well. With both sides completed, Alba rolled on thick coats of Kirker primer, paint, and undercoating to protect the new frame section from the elements.