rusty floor repairs and custom stereos

[cleatus]

Just got this XJ about a month ago. Its a 91 2dr 4.0 4x4 with 160,000 that I got from the US Fish and Wildlife.
I think it was a pretty good deal for $700. Its up-to-date on all engine repairs accoarding to the stack of repair sheets they gave me.

pics of the buff job on the oxidized tree sap paint:
http://www.cleatus.org/xj/xjbuff.htm

pics of the rusty floor repair that I had to fix (must have been the musty smell)
http://www.cleatus.org/xj/xjfloor.htm

pics of the custom subwoofer enclosure and stereo install I did
http://www.cleatus.org/xj/xjinside.htm

now all I have to do is get it inspected so I can install the 4.5" lift sitting in my living room

 

[adrian barr]

very nice work dude. I have had my 96 for about 3 months now and the musty smell is getting more noticable . Dont want to rip up the carpet just yet. Did you rivet in new pieces ?? what did you use to seal them ??

 

[aparke4]

if you can weld not rivet but it definatly looks welded to me! nice install on the box and floorpan job durabak/ herculiner is a must for every jeep.

 

[cleatus]

I actually welded the new floor pan sections, then I sealed them with RTV. After that (which I didnt take a picture of) I actually fiberglassed all of the weld seams. Its waterproof as a boat now.

 

[adrian barr]

So finally got off my a## after reading this post. Ripped the carpet and lining out of the back. Definately the source of the funk !

The padding under the carpet was soaked. Good news is very little rust:roll: just a little around the tie down points.

 

[joecool]

Very nice job! I especially like the speaker and subwoofer enclosures. One of these days I need to get around to fixing my floors.

 

[Menzenski]

Great job on the floor. How much durabak did you use, and where'd you buy it? I'm about to order some bedliner, and am wondering if a gallon will be enough (doing rocker panels and wheel wells too).

 

[cleatus]

I ordered 1 gallon from the duraback website, it cost about $100.00 shipped to my door. I did all the rocker panels and coated the floor with 2 coats and I still have about 1/4 gallon left. I cannot give enough praise for durabak the stuff is amazing.

I had the same problem, the padding under my vinyl flooring was soaked! at least you dont have the rust issues, just wire brush it and by the rust killer from advance auto. Then prime it and paint it.

 

[cleatus]

Oh, and one thing I have noticed is that I have zero road noise now!

 

[dizzymac]

What did you use for a welder (stick/wire feed) and what guage is that repair sheet metal?
I'm in the middle of doing mine, yours had about 60 % less rust than mine. I gotta take pics.
I plan on bedcoating mine too, after sandblasting and Zero Rust the entire floor pan inside and out, along with the "frame" rails (which I'm glad did not rot out, theyr'e about the only thing that kept me from falling out....lol).
Good job..looks great.

 

[xj-fx]

I ripped my carpet out a couple weeks ago so I could weld the cage in.. I am going to Line-X the inside. The smell has cleared up considerably since the nasty carpet was torn out. If you are driving an XJ with some age on it I recommend the extraction...

 

[cleatus]

What did you use for a welder (stick/wire feed) and what guage is that repair sheet metal?
I'm in the middle of doing mine, yours had about 60 % less rust than mine. I gotta take pics.
I plan on bedcoating mine too, after sandblasting and Zero Rust the entire floor pan inside and out, along with the "frame" rails (which I'm glad did not rot out, theyr'e about the only thing that kept me from falling out....lol).
Good job..looks great.

I used a mig welder (gasless) with 22 guage sheet metal. If your whole floor needs replaced or if they are bigger sections I would go with at least 20 if not 18 guage, just have to set the welder at a slow wire speed because the existing floor pans are pretty thin stuff.

 

[cleatus]

Also the leak or water in floor was coming from my windsheild, seems as though it rusted underneath and let water come inside. The windsheild guy let me grind it down and prime it before the new windsheild was put in. It had a crack in it so I had to replace it before I could get it inspected, otherwise I probably would still be looking for my leak.

 

[dizzymac]

I have a stick and a MIG, but prob. will use MIG, although I'm better at stick. Will be using 18ga. to replace the biggest part of the floor. Only thing that will remain of original floor is tranny/DS hump. I have the rear torn out now, what a PITA, dropped the gas tank, breathe a little easier with it out.
Figure I'll replace the rear shocks, rear brake lines, rear stab. links and bushings while I have the tank out. Will sandblast it all and refinish and just work my way forward.
Mine is rotted so bad that the rear seat (upper portion) rotted out where attaches to the wheel well as did the wheel well.
I'm going to have to check my windshield too, I do have a leak,overhead console fills up in when it rains,can't seem to locate the source but I wouldn't be surprised if there's rot around windshield, why should it be left out...lol

 

[cleatus]

10 bucks says its your windsheild, because my headliner would fill up with water when it rained or when I would wash it.