Project Rust bucket

Following on from my queries on how to fix it ( www.bigjimny.com/index.php/forum?view=to...=7&id=55843&start=12 ) ive finally found some time to put up my thread. :)

Here it is back in Nov 2014, just purchased with the understanding it needs some minor welding for MOT. All i have to do now is drive it 250miles to get a 3Hr ferry crossing in torrential rain and gale force winds


Got it home and stripped the rear out to see what we were dealing with and what it would cost to have it welded...


Needless to say this was the tip of the iceberg!

After some digging i came to conclusion that i wouldnt be paying someone to fix it and id be learning some new skills lol.
This bit just fell off when i removed the bumper


Body mount holed and mounts no longer attached to body


Front end rotten too


Most of the bad stuff removed from the back


Plan of attack was devised,
Aquire a mig welder uncle had hobby spec SIP150 that he never used prefering Oxy/Aceteylne brazing/welding
Learn to weld a little

Repair chassis mount


Repair/ replace body mounts

2.5mm box section with 3mm angles plug welded internally to rear pillars/door frame (double/triple skin areas), remenants of rear panel and internal rear arches rebuilt with 2mm plate and welded to box section. Finally 5mm steel plates with original mount posts welded on. Seems to have worked fine.

Put in new Metal where required.
My method
Area to replace

Clean and remove until you hit solid metal

Repair the easy bits

Template the more difficult

Weld it up


Boot floor/arches patched, Fully down both sides, new jack recess made, lots of new metal added in.




Looks straight forward written here lol

So finally after 3 weeks of grinding, welding, cutting and 3 stitches in my knee due to "grinder incident" it was ready for MOT....
Or so i thought! as id been preoccupied with adding new metal back in id forgot to check normal stuff! Turns out driver side king pin bearing was shot.
It didnt fail to live up to its name of Rust Bucket! Every nut and bolt disentigrated! im not kidding when i say i think i managed to get 1 bolt out using the standard size socket, every other bolt had an undersize socket hammered on, vice grips used or when all of that failed (maybe 6bolts) i had to weld something onto them to get some heat into them and give vice grips some purchase then keep the heat on with a blow torch to finally remove them.


Some 3 hrs later i had 1 side stripped! 20mins later it was back together with new bolts

So MOT then


- at least it didnt fail on any of the stuff i had done
Dodgy sill


Suspected crack in chassis - turned out to be surface rust on a previous repair, was cleaned up and seemed sound


so more welding - 3mm plate welded into section of chassis that was looking suspect.


Minor fire


due to hole in floor whilst welding sill


more welding


All done -


I actually forgot to take a picture once everything was sealed and painted before the interior went back in

Thankfully it passed MOT this time
So it had its first outing that weekend

With the Mutt who was the main reason for buying the jimny or so the wife could drive it in the snow
Not sure he gets how its meant to work though!


and a few more




First Mod, 16" Grand Vitara wheels and 205/80/16 Insa Dakars seems to be around 29"


Even got some Snow to try them on


Some underbody protection made up - seems a sin to use 10mm Carbon Fiber plate for bashing on rocks but its all we had in the work scrap bin that would do. Interesting to see how long it lasts.

Deffo easier to weld the 6mm brackets up for the transfer box guard than the 1.2mm for body work.

Test fit - Bolts were all properly orientated for final fit.


Ready for some fun


Got a couple further mods done (discreet winch and body lift) ill post when i get time again.

Bloody hell! That was a project and a half!!
Cracking job though- many (including me) would have given up on it!!
Looking great now and is the best of the Jimny colours!

Crickey! That was a scrapper in my mind! Well it was before you learnt to weld!

What an awesome job you've done!

Did you get a new door card and seat after the minor fire? There's a lesson learnt there I guess!

Kirkynut

Thanks for sharing 10 out of ten for sticking with it ...... :ohmy:

A good job well done but you didnt need to undo the 4 bolts behind the hub 100% for effort

Good job your handy with that mig welder , hate to think what that would have cost you otherwise ££££


Minor fire


Damn that would have pissed me off, now you can get even less in them silly door pockets :lol: