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Thread: another xj 2x6 tube rocker build

  1. #1
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    another xj 2x6 tube rocker build

    I'm going to tackle this soon. My very first weld ever is on the left, and my instructor's welds are on the right.

    I have 2x2 1/8 angle, 1" 1/8 strip, and 3/16 thick 2x6.
    My welder is a Lincoln mig, 120v migpac140. I'm using autoweld gas. I'll probably use .035 wire because I was given a giant spool.

    I might get 1/8 thick 2x6, but I'm not sure yet, I'm taking baby steps.

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    Last edited by big_ang; 11-12-2013 at 06:51 PM.
    Angelo
    1998 Jeep Cherokee - 2dr, 4.0, Auto, 231 4x4
    1980 MGB - 3.4V6, T5 transmission, Ford 8.8 posi.
    1989 Dodge Daytona Shelby - t-tops, 5 speed, 2.2 intercooled turbo

  2. #2
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    cool...looks like you've been spending time on the welding tips and tricks site

    i've had a 180 dual for a year now i haven't even plugged in yet lol

  3. #3
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    After being unsuccessful in finding someone that could help me (or do it for me) I've decided to get started and see what happens. It's much worse than I thought.

  4. #4
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    Quote Originally Posted by big_ang View Post
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    After being unsuccessful in finding someone that could help me (or do it for me) I've decided to get started and see what happens. It's much worse than I thought.
    I am currently puking. Wow the rust really got ahold of your XJ. Good luck Angelo with the repair
    IT'S TWEETER B!TCHEZ
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  5. #5
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    I am going to be tackling this same project in the next 2-3 weeks. My quarters look almost as bad as yours, but I think I have more good metal to work with around the rockers. I have a small frame patch I will be doing once the rain goes away, then I will be getting into the prep work for the 2x6 mod.

    With you being a little ahead of my mod I should be able to follow right along.

  6. #6
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    Not much progress today, I went shopping and picked up a Lincoln welding shirt, sleeves, hat, gloves, pliers, mig wire, etc...
    All I did was cut the ends of the 2x6 on a 45 degree. The chop saw couldn't cut it in one shot so I had to also use a grinder. I took a lot longer to cut than I thought. I feel like most of the time will be spent cutting metal.
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  7. #7
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    Quote Originally Posted by big_ang View Post
    Not much progress today, I went shopping and picked up a Lincoln welding shirt, sleeves, hat, gloves, pliers, mig wire, etc...
    All I did was cut the ends of the 2x6 on a 45 degree. The chop saw couldn't cut it in one shot so I had to also use a grinder. I took a lot longer to cut than I thought. I feel like most of the time will be spent cutting metal.
    Click image for larger version. 

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    The cuts turned out good in the long run, so if you are not in a rush it is better to take your time than rush and have a sloppy job. I will be doing all my metal cutting with either an angle grinder or my P Auto portable bandsaw. I do have a special shaping tool to make up for the deficiencies in my cutting equipment.

  8. #8
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    Lookin Good man, glad you are giving it a shot. If you want any specific pics of mine let me know. Also if you know anyone else who wants to do this, let me know, I have steel to get rid of that will be perfect.

    Matt
    The OG HOISTWAGON
    99 XJ, CT Motorsports built, Tons, 37" MTR/Ks, TMR 3-link and Beadlocks, CrewFab Cage and Bumpers, PSC full hydro

  9. #9
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    Update:
    Not much progress has been made in the last couple of weeks as I was on vacation in Boston and NY. I got most of the passenger side done before running out of autoweld.

    I learned 2 things from the bit of work I did before going on vacation:

    1 - Cover your windshield!
    Some sparks hit the windshield and embedded bits of metal in the polymer, so now it looks like my windshield has specks of rust.

    2 - Take off your door panels
    I didn't remove the seam sealer because I knew it would be easier to remove after it got a bit of heat. I didn't expect it to catch fire and burn my interior door panel.

    I needed a new passenger door anyway because of rust (the drivers side is mint). I'm on the lookout for a "deep amethyst pearl" passenger door with the interior panel. If you have one, please let me know.

    I'm also in need of fender flairs. Hopefully I can get a set from a TJ to use on the rear.

    I got more gas and will work on the rockers again next week. If I get flairs I'll be done, otherwise I might drive around with no rear flairs.

    Burned door:
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    Rust removed:
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    The plan:
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    The first welds. I know it's bad but I got better after I somewhat figured out how to weld.
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    Last edited by big_ang; 07-24-2014 at 02:24 PM. Reason: adding pics

  10. #10
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    I will be watching this like a hawk I also have to do this soon

  11. #11
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    I have deep amethyst pearl doors but I only have the one set and they are on my XJ and match the deep amethyst pearl body nicely

    I am guessing that you cut back the inner rocker so much due to rust, I am hoping that my inner panels are solid so I can just use the same method as in this 2X6 rocker install. I haven't cut out the outer rocker yet because I want to do my quarter panels first. I should be getting to them in the next couple weeks but I have to finish up the mechanical on my other car.

  12. #12
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    Finished the passenger side rear lower quarter today:
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    So far I used 025 wire. I switched to 030 when I cleaned up and finished for the day.
    Bondo and my grinder will be my friend.

  13. #13
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    Started the drivers side today:
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  14. #14
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    I'm working on it today and managed to set my jeans on fire:
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    I don't know what I'm doing. Anyone want to help/take over/buy the heep?

    I can't figure out how to close the drivers side lower quarter:
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  15. #15
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    Looks like you are going to have to do a little rebuilding on the inner fender, then just weld in so sheet steel to close off the big open hole you have left. It looks like we have about the same amount of fabrication to do in that area, but I wont be starting mine till I buy new quarters in another few weeks. I have too much rust around the wheel opening to be able to fabricate that part

  16. #16
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    Almost done:
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  17. #17
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    Here's the other side done for now (I know my door is rusted):
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  18. #18
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    Doesn't matter that the door is rusted, it can be fixed. What does matter is that your rockers look sharp. when I do mine I plan on running the full length from wheel opening to wheel opening.

  19. #19
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    Looking good Ang. I'm about to do mine too - also a 2 door. I currently have the floors out on the passenger's side and the rocker removed. I'm using 2"x6"x0.120". Everything is cleaned up and I'm starting to cut and fit the new rocker but I want to address the front leaf spring hanger while I have good access to it from above. The metal is OK but the bolt through the bushing is seized.

    I plan to do the front end of my rockers pretty much like you have (no offence George). One of the problems I have heard of is that if you take the rocker right to the front wheel you may have drainage problems. That's not a big deal in the summer but if you run your Jeep year round ice can build up on top of the rocker at the front bottom corner of the door. It's less of a problem at the back corner of the door as you can easily clean the ice out.

    I'm in no rush to do mine - too many other projects on the go. When I get into it more I'll start a thread of my own. I'll be watching yours in the meantime.

  20. #20
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    I like the way it turned out so far, but if I were to do it again I would probably cut the bottom of the front fender and go the full length.

    I'm going portaging in Algonquin this weekend and needed to put the xj back on the road for the trip, so I'm leaving it as-is unpainted. Next week I plan to install a set of rear TJ fender flairs, which means more cutting and welding. Once I'm done welding everything, seam sealing everything, and finally painting I'll be completely finished this project. It's definitely a lot more work than I thought.

    The 2x6 sticks out 2" and slopes downward, so water/snow shouldn't build up on the ledge too much.

    Also, I welded the 2x6x3/16 directly to the sheet metal under the doors, which wasn't as hard as I thought it would be. I was going to use a 1x1/8 flat like the "2X6 rocker install" link above, but (and correct me if I'm wrong) I found it unnecessary.

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