1992 Wrangler YJ with multiport fuel injected 4.0 liter engine, AX-15 five speed transmission, NP231 transfer case, Dana 30 front axle and Dana 35 with Trac-Lok rear axle.  Purchased on 8/13/08.  Complete rust through of the frame by the rear shackle mounts is the major issue.  Other initial issues to be fixed include large rust holes in the floor boards and rusted out body panels as well as an oil covered engine hopefully from a leaking valve cover gasket.

The rusted frame is a significant safety concern since it is by the main rear supports.  The frame is extremely thin for several inches all around the holes.

The rust holes in the floor and sides are the next major concern.

The engine's oil leak is minor compared to the rust issues.  You can see where I wiped the oil off in front of the distributor.

Repairs started on Labor Day 2008.

 Preparation and clean up in progress.

Diamond plate being fitted.  Metals Depot at http://www.metalsdepot.com is a good source for metal stock with fast service.

The body panels that will be under the diamond plate were sanded then coated with West Marine's Rust-Lock before priming with 2 coats of Pettit's Rustlock Steel Primer. These products are designed for salt-water environments and Wisconsin has lots of road salt in the winter. Both products are available at http://www.westmarine.com/  Finally they were coated with two coats of Herculiner.  The junk parts are from my 1971 CJ5 project and my 1980 J Series pickup.  These projects are also on Car Domaim.

Floor repair panels being fitted.

The cockpit area was sanded then coated with West Marine's Rust-Lock before priming with 2 coats of Pettit's Rustlock Steel Primer.  Finally it was coated with two coats of Herculiner.