BLKXJ 96

AND.........HERE WE GO!!!!!!!




I have no idea how this will end up, but Im going to cut out the rusty pan and weld in a new complete floor pan. For the most part everything looks good-ish, I still need to drop the gas tank and drain the fuel lines so I can start cutting and welding. I will post pics of my progress as I go along and get things done.

Jamie57

WoW. I thought mine was bad!
I hate rust.
I just slid out my front and rear axle and slide a new(er) Cherokee over them.
Have fun my friend!

BLKXJ 96

I did the front pan a few years ago, the rear looks pretty easy.

jd4x426

thats alot of rust good luck i foresee lots welding and cutting for your future

BLKXJ 96

Im installing this

Floor pan: Part # 55175177 AD

Inner fenders: Part # 55000147 right
Part # 55027694 Left

Fill tube housing: Part # 55345623
Part # 55235533 AC

FlyingLow

You and I are in the same boat man. I'm gonna have to replace the front and rear. I just don't have the ***** to cut it all out as it's my dd and if I Ef' it up I'm beyond screwed. Good luck.

BLKXJ 96

I just sailed past the point of no return, the waters pretty choppy

Jamie57

on your rig?
Had the carpet up on my 98 to wire in the trailer light harness and noticed quite a bit of rust. Kind of startled me as I had been underneath and the MAIN reason I purchased this jeep, (besides the price Muahahahahaha) was NO RUST from underneath. I mean it's perfect under there! but I have more rust under the cargo carpet area than I would like. Nothing rotted through yet but I'm thinking I gotta call my bud with the sandblaster and do some major rust painting!

So is it a major roof leak? Really bad seals around the rear hatch? Everything looks REAL good but am I missing something?

BLKXJ 96

Gut all the carpet and water test it with a garden hose, repair all the leaks. then use roll on bedliner in the whole interior, the bedliner will help stop the rust. Then put your carpet back in, it is easier to water test with the carpet out then you can see where the water is coming in at, and it is not hidden under the carpet.

94xjstud

Well since you are basically missing the back half, you might as well cut it all off and tube it.

Jamie57

Sounds like a plan!

92muddycherokee

Where did you get that replacement pan?
I have about the same amount of rust as you on my 92.

BLKXJ 96

Jeep dealer, it was being discontinued or "NS1" I only payed about $75 bucks for it IIRC

I have a big list for the parts department in the morning.

DJKnightmare

WOW I like that replacement pan. Hope I can find a deal like that.

BLKXJ 96

I have got all the old floor pan cut out, most of the rust ground off, the rest is going to get wire wheeled and POR-15 brushed on it. I ordered both right and left wheel tubs, the structure for the gastank fill tube, and the back plates to both rear rockers. I spent most of the day saturday reconnecting the body to the frame rails at the back that had broken off, so the Left rear section could be lifted up about an inch. I made a few brackets and used heavy duty steel structural rivits because I think they will hold up better than a weld.
When im done the body of the jeep will almost be rust free