- For best results use either 6011 3/32 or 1/8 welding rod or .035 wire with a 75% Argon/25% CO2 gas mixture
- Thoroughly grind and clean surfaces to be welded
- Stitch weld using ½ inch to 1 inch long beads every 1 inch, then weld seams
- If not confident in your welding skills, hire a professional welder. Check out our website for recommended installers.
- Check for any fuel leaks and repair before installation
- Keep flammables at least 20 ft. from vehicle
- Place a fire extinguisher and hose nearby during installation
- Use a fire watch person while welding and cutting
- In case of emergency call 911
- Use eye protection and gloves during installation
Repair only one side at a time
- Lift Jeep using jacks/ramps/lift. Make sure Jeep is completely supported on all 4 corners.
- Support transfer case. Remove transfer case mounting bolts and skid plate.
- Mark area to be cut. Transfer a mark from one of the original bolt hole locations to the frame above where you are cutting. You must cut away at least ½” from the bottom of the frame. You can remove more depending on level of rust. Leave at least 1” of the frame at the top for the kit to overlap. See Diagram 1
- Cut away the rusted area
- Slide the kit into place, pushing it tight against the frame. Mark where it is to be welded
- Grind marked areas clean down to bare metal
- Slide kit over frame once more using Diagram 2 or 3 for proper placement
- Clamp kit into place, temporarily bolt skid plate up to get exact alignment, and ensure transfer case is also lined up. Tack weld kit into place then remove skid plate and weld 1” beads around all edges. Continue to weld until all seams are solid.
- Prime and paint
- Double check welds, skid plate mounting, and transfer case mounting
- Lower Jeep. Test drive. Inspect again after 1 mile.