leaf spring broke floorboard

[4x4troy]

ok the mount that the front of my leaf spring bolts to on the drivers side is well broke, bent and rusted.it looks as if someone tried to reinforce it at on time with some plates...both dr and pass side has the plates...here are some pics to show it better...the spring has came through the floorboard....

here is the under shot
https://www.supermotors.net/getfile/831791/fullsize/100_0053.jpg
https://www.supermotors.net/getfile/831790/fullsize/100_0054.jpg


from the inside
https://www.supermotors.net/getfile/831789/fullsize/100_0058.jpg
https://www.supermotors.net/getfile/831788/fullsize/100_0057.jpg

[4.3LXJ]

As if it wasn't obvious, Dude you have some major rust going on there.

[bluedragon436]

Yeah I am not sure how much you can enforce rust... that does def. suck right there though... time for some upgrading/modifications...

[4x4troy]

i am thinking of cutting all the bad out and cutting a good section out os another xj and welding it in....just the sub-frame has me alittle worried.

[JENSSEN]

Cut out your rockers weld in square tubing in place then brace the rockers to the Unibody rail with plate or angle iron make new tabs and voilÃ* it's done I can post pics on how to do it

[4.3LXJ]

Cut out your rockers weld in square tubing in place then brace the rockers to the Unibody rail with plate or angle iron make new tabs and voilÃ* it's done I can post pics on how to do it

It can be done. But you need to get rid of that rusted out area first and start over.

[4x4troy]

yes jensen please send some pics

[JENSSEN]

http://www.4x4wire.com/forums/showflat.php?Cat=0&Number=1130183&page=0&fpart=12&vc=1

look in this thread on the page I linked, you can see the square tube rock slider thats in the factory rocker panel area,.. I will post up my XJ set up when its light out and I can take some pictures

[bigjim350]

Time to build a buggy

[JENSSEN]

Too bad you wern't closer, I would have that fixed on a saturday and the fix will outlast the rig! Pics are coming tomm of my fix

[bluedragon436]

Time to make some boatsides... then build up some new boxes off of them...

[pingpong]

POlyPerformance makes some new rear leaf mounts... they are weld/bolt on. check them out

[bluedragon436]

I know that Andy (IronMan) (http://www.xjtalk.com/showthread.php?t=4821) is looking at making some up as well, correct me if I'm wrong!!

[Mudderoy]

I know that Andy (IronMan) (http://www.xjtalk.com/showthread.php?t=4821) is looking at making some up as well, correct me if I'm wrong!!

Yep, but he needs to get 10 people together so he can make the cost worth it. I know anything he builds will be bad a$$ strong.

[4x4troy]

thanks jenssen.it will be fix that is for sure.not going to junk it like some other sites are saying....and they suppost to be hardcore jeepers...lol.
anyway i plan on ripping the interior out today to see how bad it really is(see how much sheetmetal i need to buy).and then start fixing it.it will take a while (i have a few ideas i will try).but when it comes back out it will be super stout and 7 passenager(i got 5 kids).
it will be a trail truck but also could be a dd thats how dependable i will make it.i have confidence in my work,just as you do.it really good to see other people that is not affaid to really work on their rigs.my hats off to you jenssen.

[JENSSEN]

Thanks man! I will see what I can put together in the next bit on the two different trucks that we have modded like this. When your done you can put a jack all on the rocker and lift the rig by them :)

[4x4troy]

sweet.i would like to have hi-lift jack points all around it...never know what can happen..lol. i really think you will like my idea on what my big mod will be...lets just say it will be very unqiue.i will pm you later will some of the details.

[JENSSEN]

OK here is a coles notes build on the Montero that just got new rockers,.. first we got some steel that measured simular to the size of the factory rocker,in my XJ I believe I used 2x4 box so the rocker stuck out past the door to protect the body panels. So first off we cut down the tube to slide in behind the skinny part of the rocker at the front.

http://i651.photobucket.com/albums/uu235/RACE4THECURE/8598ab5c.jpg

[JENSSEN]

Once its welded up and capped the rocker gets cut out, now in the Montero we went stealthy to look factory on the XJ we removed the whole rocker short of the backside ,..

http://i651.photobucket.com/albums/uu235/RACE4THECURE/259316cb.jpg

[JENSSEN]

You will notice in the picture the plug holes cut in the backside tin to attach the new rocker,.. the new metal gets butted up against the factory rear panel, and fitted to be level

http://i651.photobucket.com/albums/uu235/RACE4THECURE/db95a9b5.jpg

http://i651.photobucket.com/albums/uu235/RACE4THECURE/7097fe39.jpg

[JENSSEN]

Once the panel is fitted you weld the existing rocker tin to the tube, plug weld the rear section to the factory back panel

http://i651.photobucket.com/albums/uu235/RACE4THECURE/6321a6c0.jpg

Now in your case I would then take a piece of plate and run it across the rotted section of floor to the uni-body and build your new spring hanger on that plate (pics to come of mine) and brace the "new" rocker in 2-3 spots back to the uni-body (use bolts to attach as some places get really picky about welding to a uni-body)

Hope that has enough detail to get you started I will post up mine that I did 5 years ago with zero failure and several wickked hits on them,..

[4.3LXJ]

thanks jenssen.it will be fix that is for sure.not going to junk it like some other sites are saying....and they suppost to be hardcore jeepers...lol.

Troy

Glad you are going to tackle this. I refrained from posting advice because I wasn't sure of your fab skills. But it sounds like you are going for it.

The secret of uniframe repair is simply to spread it out. On a frame, you just find a good spot and weld or bolt on what you need. But a uniframe has its strength as a combination of structural parts spread out over the top and bottom of the vehicle. So the rock rails are a good start and not hard to put in. Just cut out the rockers and use whatever size you want there. Jensen used 2X4 tubing, many use 2X6 so it sticks out a little to protect the body a little better. Personally I like the 2X6. Once you have done that, I would suggest plating your sub frame as best as you can. Then tie the two together and then weld on your spring hangers. I would suggest doing both sides. And before you start, support your rig with jack stands and make sure there is no twist in it before you start to weld. Also weld small sections at at time to keep from putting too much heat into the existing metal.

[4x4troy]

yes sir.once on jack stand i will plumb bob it and make sure she is perfectly level.i will also be using the poly kit.their rear spring hanger kit and front long arm kit and i will build the rest off of that.i will use 2x6 for rockers. i will probably tie evrything in with 1 5/8-2" tube.and also plate the rails...pretty much build a frame for it.

[JENSSEN]

Troy

Jenssen used 2X4 tubing, many use 2X6 so it sticks out a little to protect the body a little better.

I think you are correct I do believe I used 2x6 I will measure tonight,.. it was 5years ago at least in my defense,.. LOL

[4x4troy]

oh and far as my fab skill go.10 years ago i built a little 89 mazda b2200 truck it was only 2wd and lowered but i put a 375hp 302 in it with a c4 auto and a b2600i rear.i made all the motor mounts,radiator supports and tranny mounts...its still driving today.a friend owns it now.i have also built a 90 rx7 with a 302.i put a 5spd in a 90 lincoln lsc mk7,built a 1300 hp 70 torino,and i have built numerours tj,zj and cj's....this is my 3rd xj . granted most of them did not need this much rust repair or mods(except the mazdas...lots of fab there).but i have the can do attitude and if someone says "oh it can't be done"well its on then time to get it done.anyways thanks for tha advise and i really like this site...way better then some other so-called xj sites.its my home page now...lol

[bluedragon436]

Yep, but he needs to get 10 people together so he can make the cost worth it. I know anything he builds will be bad a$$ strong.

Yeah I was kind of thinking the fact of his stuff is def. build to be pure beef... was why I was thinking might be the best deal for the money and purpose spent... especially cause no only would it help angles and such... but would give this guy a great replacement at the same time...

[4x4troy]

ok i think iwill give ironman a shot and hold off on poly .now we just need 9 more people to get them

[bluedragon436]

I wish I had the extra money to spare... I would go ahead and upgrade to a better and beefier design for sure...

[4x4troy]

not much has happened with the jeep.might be tearing it apart next few days to see the damage.i also found a replacement body in my neigborhood.....hopefully i can get it cheap.if nothing eles for parts.it a 2wd but that can be fixed easily.

[bigjim350]

I have to agree with you 4x4troy. xjtalk is by far the best xj website on the net. Everybody is super friendly with great attitudes. And there are alot of smart people here that will ALWAYS lend you hand or advice.

[bluedragon436]

I def. enjoy XJTalk that is for sure... I feel bad for having so much time away from here, after I first joined... not by choice I assure you!!!

[4x4troy]

well the body i found in my neighborhood is not for sale....could not talk the lady out of it...oh well.

[Punisher]

damn salt from the snowy roads will rush the hell out of the underbody... thanks god I live in florida...:driving:
nice work though..:thumbsup:

[4x4troy]

uh...i live in the jax,fl area....this jeep came from lake mary,fl...atleast thats what the title says...lol

[bluedragon436]

Yeah I live up north... and they love to salt the hell out of the roads up here... so I am def. paying attention to my Jeep... after the salt is cleared from the roads I hit up the car wash and wash the whole jeep including the under side... I def. dont' want to have my mounts and such rusting away..

[modestmar00xj]

yeah that a pritty weak area but deff fixable!

[BrianXJ]

I was searching around and found these floor pans.

http://www.discountjeepparts.com/product_info.php/cPath/3121_3123_3136/products_id/23946

http://www.discountjeepparts.com/product_info.php/products_id/28548

Maybe a fix as well instead of just buying the sheet metal. They are pre-formed and ready to be welded

[modestmar00xj]

Good job on taking on the job off fixing the xj! and yeah xjtalk is a awesome website! everyone helped me answer a lot of my questions! cant wait to see more pics!

[JG-Man]

Is this thread dead (2010)? I would love to do the same thing 2x6 steel tubing in place of rotting rockers - before it gets too bad. Rust started to come thru the rockers. I didn't give up when a tree fell on it. Now it has like new sheetmetal most everywhere EXCEPT the rockers/unibody/subframe.