2003 Jeep Rubicon – Full Rust Repair & Restoration

Starting Point

This Jeep came to us with over 600,000 km on the original engine, extensive rust, and severe structural issues. Torque boxes, floors, and rear quarters were heavily corroded—honestly, it should have been sent to the junkyard. The original plan was a simple paint refresh, but the condition demanded much more.

Project Scope

• Originally intended as a quick paint job

• Expanded into a near-complete restoration due to severe rust

• Owner had sentimental attachment, so the decision was made to save it

• Entire Jeep sandblasted and refinished, minus removing the tub

Paint & Body

• Full sandblast of all panels, bumpers, and undercarriage

• Hand-fabricated panels for rusted or missing areas

• Rear quarters, torque boxes, and evap mounts rebuilt

• Coated with 2K epoxy primer, base, and clear finish

• All metalwork and body prep done in-house to OEM-level fit and finish

Mechanical & Performance

• Owner installed new engine bearings after restoration

• No other major drivetrain modifications

Interior / Electrical

• Floors replaced on both sides due to rust

• Interior otherwise left stock

Fabrication / Custom Work

• Extensive hand fabrication on rear quarters, torque boxes, and mounts

• Structural integrity restored to modern standards

• All undercarriage components carefully repaired and coated

Challenges

• Rust and rot were worse than anticipated

• Project expanded significantly from a paint job to full restoration

Final Result

• Jeep is fully restored, structurally sound, and visually striking

• Retains original charm but now built to last

• Perfect balance between capability and aesthetics

Media

• Multiple before/after photos

• Full YouTube video documenting the restoration process