How to Apply Durabak Polyurethane Bed Liner to Your Jeep Wrangler

October 8th, 2010 by admin

Jeep Wrangler Bed Liner

After doing some research and asking the helpful guys at my local 4 Wheel Parts store in Lynnwood, Washington, I decided to purchase the Durabak polyurethane bedliner for my Jeep. I was told that I would only need a single gallon to cover the entire inside of the tub with two coats, but to be safe I purchased an additional quart (this turned out to be unnecessary, but better safe than sorry, right?).

In my last entry, I detailed how I removed the rust from inside the tub of my 1992 Jeep Wrangler. At this point, the entire inside of the tub was clean and primed with Rust-Oleum Stops Rust Primer in flat black. I also masked off the dash and other areas I wanted to keep paint-free.

The manufacturer’s directions for application of the Durabak bedliner state that a primer coat is not necessary, but I found that the bedliner adhered much better to the primed areas than the places where I had just roughed up the paint with a light sanding, as recommended.

Application was pretty straightforward. I used a foam brush to paint the smaller areas, while my helper covered the larger parts of the tub using a roller. We did our best to work quickly, since Durabak is a moisture-cured compound and, typical for Seattle, the weather was drizzly and wet. The first coat went on smoothly, though it did take us a few minutes to really get the hang of how to apply the bedliner evenly. Since the air was so wet, the first coat set up fast. We let it sit for 2-3 hours before applying the second coat just to be sure it was good and dry. Once the second and final coat was applied, we removed all of the masking tape and paper and left the Jeep to dry overnight. The next morning, my helper and I inspected our work and touched up any areas we thought necessary. Since Durabak bonds to itself, this was no problem.

Jeep Wrangler Interior, Durabak polyurethane bed liner

For the drain and bolt holes, I wadded up strips of painter's tape and stuck them in the openings so they would not get gummed up by paint.

And we were done! Simple, easy, and now the inside of my Wrangler is fully protected from anything the elements might throw at it. I’m very excited to see how the Durabak bedliner holds up during snowboarding season when the inside of my Jeep gets a lot of abuse. So far, I’m pleased with the way the inside of the tub looks and feels.

A few helpful tips:

1. I’ve said it before, but spend some time doing the masking. You will thank yourself when you see the final results!

2. We used foam applicator brushes rather than bristle brushes to get into the smaller nooks and crannies of the Jeep. I found that using a “dabbing” motion rather than a “brushing” motion was better for even coverage.

3. Wear gloves! Durabak (or any other bedliner, I imagine) is darn near impossible to get off your skin once it’s dried. Don’t expect it to come out of your clothes, either.

4. We used Xylene as recommended by the manufacturer to thin down the Durabak, as needed. Since the air was so moist, the bedliner was setting up rather fast and we did need to thin the Durabak for the second coat.

5. Immediately after the second coat has been applied, remove all of the masking, but do it carefully! Take your time and make sure you remove all of the tape and paper covering your vehicle.

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