Project Potimus

[Smokeyyank]

Finally got the roof rack I ordered last November, FedEx lost the first one, no clue how because the package is huge AF but whatever. Got one from Golitah offroad, it's fully aluminum so weighs practically nothing, tested fitted to make I had everything. I'll take it off and paint once I paint the WJ, but for now it will now double as my interior crap. 

 

 

 

 

 

After that was up I moved on to yanking out the interior. Going to put down some sound deadener and want to pull the carpet for the welding the stiffners and rock sliders. 

 

[Smokeyyank]

Took out the rest of the interior and carpet. I knew there was going to be some rust as it was visible from the under carriage. There was also some on the floor boards under the sound deader. 

 

Air chisel made short work of the old junk. Being like 10 degrees probably helped too. 

 

 

All old stuff out, no on to the rust. 

 

 

Sanded down

 

 

Hit it with some self etching primer.

 

Now on to the problem areas. Both sides rusted under the front rear seat. 

 

 

Driver side was worst

 

Passenger side. 

 

 

Drilled out the plug welds cut and cut it out to get an idea. 

 

 

Both are pretty clapped out so will probably cut them fully out and re weld a new bottom piece before the patch 

 

 

 

[Smokeyyank]

After that started on cutting the fenders. Marked out a trim line trying to keep it flowing with the lines already there. 

 

 

Chopped but still need to clean up some stuff. Mainly around the firewall area and the headlights.  

 

Lots' more choppy choppy coming. 

[JoeLAW]

Bitchin! I like the way it's coming along 

[Eagle_SX4]

40 minutes ago, Smokeyyank said:

Nice wheels. I have nearly the same wheels on my Comanche. Mine don't have the bead lock trim rim.

[Smokeyyank]

1 hour ago, JoeLAW said:

Bitchin! I like the way it's coming along 

 

Thanks, making progress! 

 

36 minutes ago, Eagle_SX4 said:

Nice wheels. I have nearly the same wheels on my Comanche. Mine don't have the bead lock trim rim.

 

I didnt really want the beadlock but I got them for a steal. Remind me of the Mojave wheels just with a little offset. New wheels are dirty life roadkill eadlocks.  Still need to get those mounted. 

 

[Smokeyyank]

Got the gas tank dropped

 

 

Rusted the f out. 

 

So much room for activities

 

Next I started on the rockers. I'm using the IRO rocker kit, I got it on promo for a killer deal. So rather than doing 2x6 steel got this. Surprisingly rockers are in great shape but choppy choppy. Still got a ways to go to get them off. 

 

 

 

 

Will look like this when its done

 

[Smokeyyank]

I got a replacement hydroboost and took it apart to rebuild it. This one was in really good shape. Probably didnt need a lot but swapped out a few gaskets and cleaned it up. 

 

 

 

Pic of the bad accumulator and good one. 

 

 

All bolted up with new gaskets ready to go. 

[Smokeyyank]

SO. MUCH. CUTTING.......

 

Got the rockers out, almost wish they had been rusted out. 

 

After I got the pinch seam shenanigans done, had a foam party.

 

All clean, minus some surface rust. Drivers side wasn't bad, passenger was a little crusty but nothing a little choppy choppy doesnt fix.

 

Also did a cut and fold on the lower jam, will stich the sliders in, and the piece for the pinch seam. After I cleaned up some surface rust and sprayed self etching primer. 

 

 

Passenger side

 

Then started to cut the front out for the bumper and winch. Still gotta cut a lot more but progress.

 

 

[Smokeyyank]

More fn cutting. Started on the rear, Got pieces for the rear bumper chopped off. 

 

 

The started work on the quarter panels. Will be clearancing them for the rear bumper wings and to get rid of the massive chunk of sheet metal that gets exposed with after market bumpers. Instructions absolutely suck from trailforged. Spend more time looking at the phone and drawing lines then anything. 

 

 

 

 

[Smokeyyank]

Worked on getting more cut the f out. Got the rear quarter done for the high clearance wings. 

 

Passenger side is done

 

Then test fit the new panels

 

 

Then started working on driver side. Since i kind of knew what to do didnt take forever. 

 

Both side are cut next will be tacking everything in place soon. After that moved to the gas tank tuck. Cut out the spare.

 

 

Wild how much space is in yhe rear when stuff if out of the way.

 

 

The started working on the rust in the rear passenger wheel well. Eneded up being worse than I thought. While I was already planning to trim the fender this will be more work than just that because of the two separate pieces of metal joining. 

 

 

 

Probably got about 80% of things cut out, but still got more chopping. 

 

[Smash6]

This is an awesome project! We had an 04 with the 4.7L and I loved that rig. It was amazing and I regret selling it. Out of our 4 Grand Cherokees, that one was my favorite. Can't wait for more updates!

[Smokeyyank]

9 hours ago, Smash6 said:

This is an awesome project! We had an 04 with the 4.7L and I loved that rig. It was amazing and I regret selling it. Out of our 4 Grand Cherokees, that one was my favorite. Can't wait for more updates!

 

Thanks! Excited to get it done, should be a solid rig once all finished. 

[Smokeyyank]

Started working on the floor patches. Kind of a PITA because the seat support bracket needed to be replaced as that was rusted through along with the floor board. So started with making a new bracket for the seat mounting. 

 

Not gonna talk about the hellen keller welds. Got a new machine and was messing around with settings trying to find the sweet spot. Hate welding sheet metal but once I dialed it in was a lot better. Doesn't help I didn't use smaller wire or gas. 

 

After put some primer and quick rattle can . 

 

 

Then put on the floorboard piece. 

 

All back together 

 

What it started at

 

 

Still need to clean up a few spots but otherwise will put a skim coat of bondo, prime, paint and seam seal it. Passenger side is almost done and after that will get the stiffeners done.