Jeep TJ Forum Third generation of the classic Jeep - manufactured since 1997. Known by the coil springs and round headlights. Includes the Rubicon and Unlimited editions as well

Adventures in DIY Rust Repair 2000 TJ

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Old 12-04-2012, 02:52 PM
  #11  
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Default Re: Adventures in DIY Rust Repair 2000 TJ

Thank you for the help. I will do that.
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Old 12-06-2012, 11:50 AM
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Default Re: Adventures in DIY Rust Repair 2000 TJ

Okay, so I took your advice and waited until morning.

I then tried to sand it lightly with 100 grit (it's all I had) and I tore down to the grey primer. Yes, I made the same mistake again! Impatience.

I decided to grind down with the paint stripper back to bare metal on 1/3 of the repair area, everything that had an imperfection plus a little more for blending.

I primed it with etching primer, followed by regular primer, and sprayed the basecoat of yellow over it. It turned out beautifully.

I went out and bought some 1200 grit sand paper and beveled the edges (where there was once tape).

... time for clear coat.
Attached Thumbnails Adventures in DIY Rust Repair 2000 TJ-clearcoat1.jpg   Adventures in DIY Rust Repair 2000 TJ-clearcoat2.jpg  
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Old 12-06-2012, 11:55 AM
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Default Re: Adventures in DIY Rust Repair 2000 TJ

Clear coat:

I mixed 4 parts (McDonald's Ketchup Cups) of clear coat with 1 part (McDonald's Ketchup cup) of hardener and loaded it in the spray gun.

I applied two light layers of clear onto the repair area + 3 inches for blending.

I let it dry 10 minutes and then applied a final thick layer over the area. Stupid stupid stupid. I put it on too thick. I have runs on the front and back extremities.

Anyone know how to buff clear coat to remove runs?
Attached Thumbnails Adventures in DIY Rust Repair 2000 TJ-clearcoat3.jpg  
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Old 12-09-2012, 08:46 AM
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Default Re: Adventures in DIY Rust Repair 2000 TJ

Cutting and Buffing Nightmare Situation:

So after doing extensive research on the internet, I have determined that my small imperfection when applying clear coat can be rectified by sanding the clear coat with 1000 grit, then 1500 grit, then 2000 grit wet sand paper.

I did so. It fixed it! 1 point for me.

I then sanded the entire repair area. Then I buffed the entire repair area with Rubbing Compound. After that I buffed the entire area with Polishing Compound. It was shiny, sparkly, and smoooooooth,

Note that I used to word `was`. You see, I noticed that the inside edge (the edge inside the jeep) was missing some clear coat. I did not apply it thick enough on the inside edge. It also takes me a really long time to clean my spray gun. So I went to Canadian Tire and bought an $8.00 can of clear coat spray just to do the edge.

I shook it and tried to apply it. It comes out not very atomized, big globs which was disappointing. But then it happened...... a HORRIBLE chemical reaction between the existing clear coat and the new spray on clear coat. It ate through the clear coat, right through the base coat, down to the primer. I rubbed as much of it off as I could with a rag but it was too late.

It looks terrible now on the inside edge and the inside of the door. I ruined the whole thing! The Jeep just won't let me win !! Talk about a learning experience though. I am really happy with the job other than the terrible horrible error at the end (perfectionism + anxiousness = bad performance). lol.

I plan on doing the entire Jeep this spring. One full panel at a time.
Attached Thumbnails Adventures in DIY Rust Repair 2000 TJ-jeepbuffed.jpg  

Last edited by jfilion2; 12-09-2012 at 08:50 AM. Reason: image not rotated correctly
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Old 12-09-2012, 09:06 AM
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Thumbs up Re: Adventures in DIY Rust Repair 2000 TJ

BEFORE and AFTER:

Lessons to recall for my next effort:

1. You have to be patient, let every stage dry overnight.
2. It will take 3 to 4 days to get the job done, not a weekend project.
3. You have to get the bumps out in the initial stage, you cannot spray over it and fix after.
4. Bondo dries REALLY hard, it is difficult to sand it. Do not use it unless you have to.
5. Taped edges will not bevel and blend well. Paint the whole freaking panel.
6. Do not turn the paint gun upside down, paint will touch the membrane - hard to clean.
7. Spraying is quick, cleaning the gun takes 45 minutes.
8. Do not mix a lot of paint, use McDonald's ketchup cups instead of tuberwares to measure.
9. If you make a mistake that you can not easily sand down, grind the whole panel and restart. You cannot blend a repair over a repair.
10. Let the etch primer dry overnight before applying real primer, they don't play nice together.
11. Do not use spraypaint clearcoat over your nice clearcoat. They do not play nice together.
Attached Thumbnails Adventures in DIY Rust Repair 2000 TJ-beforeafter.jpg  
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Old 12-09-2012, 07:16 PM
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Default Re: Adventures in DIY Rust Repair 2000 TJ

Nice write up - good information for when I tackle mine.
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Old 12-10-2012, 11:00 AM
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Default Re: Adventures in DIY Rust Repair 2000 TJ

The best artisans,tradesmen,and DIYers are generally self taught. Just can't beat experience,combined with patience.
looks like you have the hang of it now.
really enjoyed your narration with pics, you demonstrate a good degree of patience , persistence.
Keep it up, and be proud of what you do
Tongue in cheek---- As so many women have found out, you don't find beauty and perfection in a jar or spray can,be it from Canadian Tire or not.
Cheers.
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Old 02-23-2013, 10:10 PM
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Default Re: Adventures in DIY Rust Repair 2000 TJ

thx jean for the laugh as ive been there and done that.great haven a jeep
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