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[Brynjaminjones]

I decided to poke some brown stuff in the wheel arch whilst adjusting the rear drums in the XJ, and my finger went right through!

I now have a beautiful rust hole at the very bottom rear of the rear left arch.

Firstly, what's the best, longest lasting approach to fix this?

Secondly, will this pass MOT? I know that lots of people cut this off when they cut and fold the rear, so I'm guessing it's not structural?

Sent from my HTC One M8s using Tapatalk

[JamesH]

Take a photo just so we know exactly where it is.

The whole body is structural if you are really picky about it all but if you weld the seams back up when you do something like cut a fold of the rear quarters then the strength change is negligible (from a non-engineer, completely uncalculated!).

The best repair is cut it all out and weld in some 1-1.2mm steel plate, paint, under seal etc.

Or sell it to me for £500 and buy a Yaris   

[Brynjaminjones]

Here's a photo of it - it's pretty solid all around it, as this photo is after I hit everything with a hammer and screwdriver.
I've covered it in tape for the MOT to stop water getting in there, but I want it sorted properly!


Sorry James, I've just insured the XJ again for the first time in months and driven it to the shops - I always forget how much I love that thing until I drive it! 

[Brynjaminjones]

So, this hole wasn't an issue in this afternoon's MOT. It wasn't mentioned, and the guy even commented that "There's not any rust at all" 


As a result, I'm going to take my time in finding the best person to sort the rust for me, as it's not necessary to do a quick MOT fix.
It did fail on some other things though which I'll start a new topic on

[Dave69]

stuff it full of newspaper and fill with P38 filler, make sure its a good read for when the next owner comes to repair it

or cut and weld a patch panel in place, paint with chassis enamel = sorted

[Bubba]

metal fusion is the only answer

[Bishops Finger]

Even a dumbass like me agrees

[Brynjaminjones]

Yup, I'll get a welder on it in the new year! I have no plan to ever get rid of this Jeep, so I want it to last!

Sent from my HTC One M8s using Tapatalk

[Hillbilly]

Yup, I'll get a welder on it in the new year! I have no plan to ever get rid of this Jeep, so I want it to last!

Sent from my HTC One M8s using Tapatalk

I thought the same with my XJ. Loved it and wanted to keep it. Cost me a fortune in garage welds. The rust will only get worse, so take a few lessons in welding. Miss my XJ 

[JamesH]

If you are happy to wait 2-3 months you can come down to mine and work on it for a day or a weekend, I've got everything you will need and you can probably help me with some stuff on the YJ I need a second person for 

I might even have a rust free piece I can cut out of another XJ (that sound like I have a scrapyard full and is probably why my wife moans about the Jeep obsession).

[Brynjaminjones]

James, that sounds like an excellent plan! I don't have a clue how to weld though!

I'm always more than happy to help if you need a second pair of hands on the YJ!

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[JamesH]

James, that sounds like an excellent plan! I don't have a clue how to weld though!

Neither do I but squeezing the trigger seems to stick metal together and some thick underseal will cover up the booger welds 

[bigjeepzj]

MIG weld  the hot metal glue gun of the boggier 

[Dave69]

just because it looks good on the surface doesnt mean its a strong weld

[JamesH]

its all about penetration 

[Bubba]

hell yeah