That is a good question, and I wish I had a good answer.
Two years ago I completley rebuilt my CJ7 tub and repainted it. I put on three coats of POR-15 on the underside of the tub. Then in March of this year I started to swap on a fiberglass tub. When taking of the body I had a good chance to look at what about 19 months of exposure to the elements did to the metal tub. It was an eye opener. I found lots of places where the POR-15 had done it’s job, and many more where it did not. The stuff had flaked off in places and not neutralized the rust as I’d hoped it would. This mean more frame repair than I thought would have been necessary. The underside of the tub had held up quite well to debris being hurled against it (including one rear drive shaft… at 60 mph). But anywhere that a pinhole was found in the POR-15 rust was starting. On the inside flooring of the tub there were two coats of POR-15, one coat of primer and two finish coats of paint. This area did not hold up at all to wear, and within a matter of a few months was rusting during the deepest cold of the Wisconsin winter. The salt took it’s toll. Bolts, nuts and fasteners all became one with the tub, despite the anti-seize compound that was liberally used.
Were I to rebuild the metal tub again… I think I’d:
1. Completely sandblast the tub.
2. Cut out all rust.
3. Weld in new panels.
4. Trim and grind down any welds.
5. Use 100 grit sandpaper to give a base for the undercoating
6. Steam clean the metal.
7. Wipe the bare metal down with vinagere to neutralize the metal.
8. Seal all seams with 3M autobody seam sealer.
9. Heat the metal of the tub to about 150 degrees.
10. Seal the underside of the tub with Rhino lining, or a competitive product.
11. Spray on two finish coats of “frame paint” over the Rhino lining. Frame paint is a type of paint that stays pliable, and “flows” to heal any breaches. It’s used on lots of farm equipment. This will provide the cushioning for the under-laid Rhino Lining.
12. Use anti-seize compound on all metal fasteners.
13. Paint all exposed metal bolts, nuts, etc. on the underside with the same frame paint.
14. Rhino line the flooring of the tub.
Now baring that, I’d get a glass body!
Good Jeepin'
Larry