If it were me, I'd do a cost comparison. I know you can rent a dustless blaster on a trailer in some places and DIY. Between the cost of that, metal patchwork/welding, shaping, smoothing and prep work, you may find it's just as cheap and much easier to source a new tub.
I always thought it'd be cool to build an aluminum bodied Jeep with a potent V6 under the hood.
I like the v6 idea, not sure about the aluminum body. Aluminum dissipates heat so well, the heat from the engine and exhaust may overheat the passengers.
I’ve seen or heard of replacement tubs for $1200 and up. The low price was someone telling about a price they saw. I haven’t seen one that low.
As far as I can tell, there are 2 small rust areas that I will weld in patches. I thought at first I might need to replace panels, but the spots could be repaired with a couple square inches of sheet metal.
The media blasting may be a different story. I have no idea what it costs to have someone blast it. Anyone have an idea?