Jeep Cherokee XJ Drip, Gutter Rail Replacement

3 years ago
17

Its been about four years since I last did any major work on the Drip Rail on the Jeep Cherokee XJ. My last attempt was made with a lack of better knowledge and the use of the wrong materials which has resulted in a revisited job.
My drip rail has had an issue with corrosion in-between the seam for the entitle time i've owned the vehicle. This is normally the frist place for rust to start on older cars and its also the last place that can find it because its not visible until its too late.
Four years back I stripped the roof back, wire wheeled any corrosion, welded in some new metal and U-channel and patted myself on the back. Well the rust has continued to grown in the seam because I couldn't get to it, so this time I'm cutting out the entire side of the roof, separating the drip rail seam and making a new seamless one from 2mm box section that's been cut to form a moulding.
Its a hell of a job and I would consider it major surgery but its got to be done if I intend on carrying a roof rack and gear on it.
Thanks for watching,
Mike

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Useful Links
Offroading in Sweden - http://www.swedishepa.se/Enjoying-nature/Motor-traffic-in-nature/Off-road-4WDs-ATVs-and-motorcycles/
Road, Trail and Terrain Laws - https://www.svmc.se/smc/SMCs-arbete--fragor/Infrastruktur/Enskild-vag-led-och-terrang/
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Road Map - https://nvdb2012.trafikverket.se/SeTransportnatverket#

Jeep Spec:
1999 Jeep Cherokee XJ 2.5TD RHD.
35x12.50r15 BFG KM3's with 15x8 3.75" backspacing (-19 offset).
Lift Front - RC 4.5" Coils and N2 Shocks (3" Coil Spacer).
Front Shock Bar Pin Eliminator.
Dana 30 High Pinion with Artec Industries Lower Control Arm Mounts with modified upper mount and modified Track Bar mount.
Front RC Control Arm Drop Bracket.
Ruff Stuff Short Arm Single Himes.
RC Extended Sway Bar Links.
Dana 30 Rock Crusher Diff Cover.
Ruff Stuff One Ton OTK Steering.
6" Lift Drop Pitman Arm.
Ruff Stuff Front and Center Frame Stiffeners.
Rear DIY Frame Stiffener and Rear Frame Tie in Kit.
6" x 2" Box Rocker replacement with Tube Slider.
Modified Factory Bumper with Side Sliders.
Rear Tow Hitch Tire Carrier that bolts into Rear Frame Tie in Kit.
Modified upper Shock Crossmember for Rear Shocks
Rear Axle Chrysler 8.25 29 Spline with modified High Clearance Shock Mounts.
Rear Shocks 6.5" Trailmasters.
Rear Leaf Springs 5.5" Rubicon Express
Rear RC Shackle Relocation Bracket.
Stainless Steel Braided Brake Lines front and back.
Warrior 9500lb Winch.
Front Bumper - https://www.ebay.co.uk/itm/Jeep-Cherokee-Xj-89-01-Front-Steel-Bumper-Winch-Off-Road/324043608951?hash=item4b72811377:g:84MAAOSwxOReH4as

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