Well I'm sure I'm not the first to have been sold a dog by a motor dealer but when I got my new 1980 CJ-7 4.2Ltr Auto home and started to clean her up I realized that rather than just a touch up this was going to be a major project!  Underneath all the fiberglass and filler was completely rotten.

Now anyone reading this States side would probably wonder what all the fuss is about, CJ's are 'two a penny' so scrap it and buy another, but in the UK they're as rare as rocking horse shit and always worth saving.  At the time of this rebuild importing body panels was totally cost prohibitive (even today with online purchasing the shipping on bulky items is still a killer)  so all the rotten panels would have to be saved by cutting out the rust and replacing with fresh sheet work.

I was lucky that a good friend of mine had worked with a guy call Paul from an outfit called Autodesign that specialised in restoring classic and vintage cars.  What made this guy special was his ability to fabricate replacement panels. With the Jeeps panels being nearly all flat it should help.  Once he'd given the Jeep a once over he set too with his cutters.

On some of the panels, such as this rear wing, all we were able to save was the top section with the detailed pressings.

Amazingly, the interior sheet metal and the frame were all soundish and only needed minor detail work. 

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Unfortunately, the same could not be said for the rear quarter panels which had years of crud stuffed up into the corners which had destroyed all the body mounting points. 

Of all the sections we had to replace this was the only one that need shaping but once Paul had worked his magic no-one would ever know.

Both front wings (fenders) were rotten where they mounted to the body tub and came under the attention of the cutter.......

......before new section could be cut and welded into place.

I have never seen such neat welding before, it was so fine and clean that it made the final surface preparation so much easier. On one side, Paul was even able to graft back on the original Jeep stamping!

New sections of sheet metal were used from the front of the tub right through to the rear corners and then feathered into what was left of the original panels......

.........leaving a perfect finish with no filler!

This entire section was made from one sheet, the tan colour is all that was left of the original panel.  Rather than use two peaces like the original a grinder was used to score in a seam to match with the original join.

As can be seen in this picture the entire bottom half of the tailgate was rusted through but was carefully repaired to look like new.  Throughout the entire project the only item to be replaced was the windshield frame.  Their just wasn't enough good metal to use as a starting point.  Importing a new frame and rubbers cost almost £500.00 (US$780.00) and then we broke the glass getting it in!!

Well here's the finished item - painted in Ford 'Radiant Red' so that spray cans could be used for the insides and trail repairs!. US readers may wonder what those lights are on the front fenders, UK law requires separate amber turn signals front and rear and 'side' lights have to be no further in then 6" from the widest part of the vehicle.  They look like crap but that's the law. 

She went on to receive a new Bestop soft-top and bikini, a 4" lift and 33" tyres on 10"x15" steel rims, 4.10 gears, Detroit locker plus lots of chrome and stainless steel.  When we finally flogged the 4.2, 6 to death an AMC 360 V8 was installed making her one mean CJ-7.

My thanks go to Dave Gibbons who help with the mechanics and to Paul from Autodesign who charged a total of £1500.00 for all his efforts including all the eventual paint work.  He subsequently did a great job of cutting down the original full doors to match the top half of the soft doors al-a-wranger.

If you'd like Paul's details give me a call.