Rust repair/ body mods

[sinat01]

Ill try to upload pics when I get home but here is what im dealing with.
1999 2 Door Cherokee
built rock rails in place of the rocker panels.
I want to do the cut n fold, buut instead of folding whats left of the rusty metal. I want to cut it off and make a plate to go in there. Has anyone done this instead? and if so, how heavy of a steel did you use?

the other issue I have is the door hinge pins are worn (again) the bottom hinge is ovaled out, and I have the typical cracks around the vent in the door frame. I want to get the braces that weld in, and figure since im doing one, I might as well do the one to brace the hinges also.
Could I drill the ovaled out hole back to round, and size up a bronze bushing to go in the whole and use a bolt or pin to keep the door where it needs to be?

 

[sinat01]

 

[Bent]

You don't say.

 

[sinat01]

I really hate that photobucket sucks, gotta figure out how to upload the pics

 

[Jeep Driver]

https://comancheclub.com/forums/topic/53244-evolution-88/


First and second page I deal with my hinges.

 

[sinat01]

Ill have to check the thread out at home, work computer wont show pics

 

[jeepingben]

I did something like that. http://www.naxja.org/forum/showthread.php?t=1073367

I didn't save any of the measurements, but it isn't square so you will want to make a template before you start bending steel.

I used 16 or 18ga, I can't remember which.

Lots more pics here:
https://www.jeepingben.net/zen/zenphoto/index.php?album=2011/jeep_rockers&page=3

 

[sinat01]

if this decides to work (the pic) this is the fun rust repair I gotta do

 

[sic3335]

I had the same issue with my lower rear quarters. Rusted out too much to do the cut and fold so with the combination of an angle grinder and sawzall I cut everything off and then welded in a plate. I watched this video https://www.youtube.com/watch?v=55FCUBiCCZg and just cut along the same lines he finished with. Can't remember the exact thickness of the metal used, but it was thicker than what I cut off as the welder tended to blow right through the thinner stuff I had. I'll be doing more and fixing a small rusted spot in the floor tomorrow and can supply pictures if needed, just let me know.