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Old 06-14-2004, 11:37 PM
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Advise needed for side rail project

I'm new this forum and I hope I am posting this in the correct category.

I've nearly completed my fabrication of side rails for my Jeep Cherokee constructed of 2x5 and 2x2 tubing. I have the following questions:

1. I've completed all the welding (beginner) and would like to know what steps I need to go trough from bare metal prep to final paint

2. I would like to cover the top and part of the edge with formed aluminum checker plate. How is the best way to fasten this to the 2x5 tube? I'm concerned about corrosion between aluminum and steel and also water getting into the tubing through the fastener.

Thanks kindly for your advice

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Old 06-15-2004, 02:24 PM
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I am assuming by side rails you are talking about step plates or step tubes. ( A pic would make it a little simpler). Anyways you will need to prime coat between the steel and aluminum to prevent corrosion or coat with something like POR 15. What you can do is go to a sheetmetal fabricator and have the plate bent at 90 degrees. This wil save from having to cover in two pieces (top and side) As far as fastening the diamond plate to the steel tubes I would invest in some stainless steel countersunk allen bolts. These will give it a nice touch and not rust.You will need a proper size drill, tap, and countersink. Lay all of your holesw out so they have somewhat of a symmetrical pattern to them. You can also cover the threads with some silicone sealer before installation to prevent any water leakage into the tubes.

Kevin
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Old 06-15-2004, 05:24 PM
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Kevin45, thanks for your recommendations. I did get the aluminum bent at 90 degrees this morning and it looks great.

I used a stitch weld to minimize the warpage on my Tee joints using a mig welder, but my welds are not professional looking, since I am new to welding. To clean up the weld a bit, would I use a wire disk on a angle grinder.

Thanks for your help!
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