H3ADBANG4L1F3

https://www.facebook.com/share/iwjRfDZFcHLwNhVp/?mibextid=kL3p88

Great progress! Both of our trucks are in a similar state of nakedness. I'll be watching yours for inspo. You may be able to touch up those seals on the slider with RTV, similar to what Pizzaman did to his vent windows. https://comancheclub.com/topic/68921-1990-comanche-eliminator/?do=findComment&comment=763885

Master Jeep

I'm definitely leaning towards this, the patches aren't the greatest and it doesn't look like any prep work was done for the paint at least, you might assume the same for the welds. Welded. I'll wire wheel them a bit to check them further. I'll definitely try to clean them up a bit before I pull the trigger on new pans. There are 4 patches on each side, 8 total. Roughly half of each pan was patched.

"Bought" another 20lbs of dry ice. Got it for free as the credit card machine was down. (Score!) Driver's side is now finished. It's definitely rustier than the passenger side! Now we reach a crossroad. Do I dismantle the previous patchwork and go with new floor pans and possibly new supports ($300 for pans, additional $350 for supports, from Keyparts) or simply clean up what I have here? Most of it looks like surface rust, the worst of it is below the pedals. If I replace the pans I can access underneath those support caps and take care of any rust before it becomes an issue, but I wonder if it's truly worth it?

Resurrecting this thread instead of making a new one. Just ordered some new front fender liners from RockAuto (https://www.rockauto.com/en/moreinfo.php?pk=683371&cc=0&pt=823 and (https://www.rockauto.com/en/moreinfo.php?pk=683391&cc=0&pt=823) as well as another site (https://www.detroitmuscletechnologies.com/jeep-xj-87-96-cherokee-mj-86-92-comanche-84-90-wagoneer-front-fender-splash-shields/). Figured I'd test the fit with both as they weren't too expensive. Do you still happen to have pictures of these? I wasn't able to find the rear splash guards so I'll likely have to make them myself.

https://www.facebook.com/share/DrVoENaYpqmn7UdN/?mibextid=kL3p88

Admittedly I have no clue. I looked it over a good bit and couldn't find any identifying marks.

Here ya go Pete. If these don't do it for you let me know!

Not a fun job but the floor is now free of sound deadening (at least, the passenger side is!) 20lbs of dry ice for this one side. Messy! The dry ice freezes it solid but as soon as it gets slightly unfrozen it immediately becomes tarry and sticky. I'll be repainting and replacing it with removable Dynapad. Also did a little work on the seam sealer. It was rusted through in a few places with plenty more rust hiding behind it. I figure I'll have to remove and replace all of it along the firewall and a few other locations I've noticed. Passenger side is mostly finished, just need to do the far edge of the firewall. Working on getting the brake pedal out to access the driver's side, the brake lines are rusted shut to the master cylinder so they're getting a good soak of PB Blaster. While I was poking around I found a few janky fixes by a PO. You can see the antenna grommet just slathered in caulk above, that's after removing a good chunk of it so I could pop the grommet out. Also found these two pieces of metal sandwiched around the firewall covering up the right hole below the blower motor. Holding them on was some sort of weird shiny gelatinous material. When removing the cowl cover I also stumbled on this gem. Scraped a good chunk of that yellow crud to get it off!

Looks like this might be for sale again soon. https://www.facebook.com/groups/391114805368791/posts/1097881201358811

If I had to guess I'd say they saw some videos of leaks coming from that area in XJs. I think just the later models use a plastic insert with a foam seal that deteriorates over time.

Well I pulled the cowl cover and found this mess. Just fantastic work by a PO. After scraping a bit I was able to break it free. I suppose the good news is now I have a bit more access to get the POR15 in like ghetdjc320 suggested. Why do people cut metal if they don't want to weld it back?

Ah you're talking about this one! Not gonna lie, I was a bit intimidated by the odd shape of it. I can certainly give it a whack.

Are those different than the ones I've made? Do you happen to know what variants are out there?

Thanks! Once I get the final fit I'll definitely post them up for others. I'm definitely anticipating a Mk. 3. Lol. We'll see how it pans out when I try to put everything back in the truck! Thanks! It's a huge pain to get off - I wrestled with the nuts and studs in the engine bay for about 10 hours!

Lmao. Once I put the heater box back in and make sure everything fits I may gauge interest to see how many would purchase them. I think they'll fit all (or at least most) 96 or below Cherokees/Comanches.

Comparison of the originals to mine.

Success! Never mind the mess in the garage lol

Improvements!

I wish! About 15 minutes away is another MakerSpace with a $60/yr fee. They have one, along with all sorts of other neat tools.

Not yet! That won't come until after I finish sealing up the leaks and sound deadening the firewall. The tricky part is getting an exact replica of the OEM gaskets. After that I can easily cut them out in whatever thickness I need.

Don't get me wrong - I can use the machine whenever I so choose. I'm the head of our "MakerSpace" which has the laser etcher among other things. And thanks! I used 1" and 1/8" microcell polyethylene foam to make them. I'll be making some more (likely today) with improvements. It's rare to get it exactly right on the first attempt!

Unfortunately I don't own it, they're quite expensive! It's at the library where I work.