I have alot of damage due to rust inside my jeep, I have lots of spare sheet metal from my father in law being a welder in the past, I bought a gallon kit of truck armor coating, should I cut out old rust parts, patch up with the metal, use rtv sealant on the edges, put in rivet screws and coat entire truck with the coating? Or is there a better way to seal up any leaks? Is there a site online that makes whole jeep pans? Replacement pans to drop in and weld into place?

 

Yes those areas can be patched but they need to be welded in properly.


I think I have saw complete floor pans for some years for sale and if you have a boat load of rust that may be what you need to do or find a good parts XJ and cut one out.


If it has that much rust in the pans you need to check the rest for rust as I bet it has a lot more of it your missing.

 

Like the inside and outside of the frame rails, around the rear shock mounts, the front spring perches - on and on - all the kiss of death.

 

When you cut the floors up, you can see into frame rails a bit right? Should help with assessment.

 

When I remove the interior completely next weekend and start cutting out I'll keep you guys posted with pics of the job so I can get more sound answers

 

Something to keep in mind for your project for any metal that isn't load bearing and rusted completely to death. Used this on an old chevy some 8 years ago after cutting out and replacing about 30 percent of the floor pan the rest that wasn't super bad got coated with this and held up very nicely:
http://www.por15.com/SUPER-STARTER-KIT--Black_p_11.html

 

Just went through this with my 95 XJ floors. Bought passenger side replacement panels from Keyparts. My welder cut out the old floors and welded these in place. Then we seam sealed the edges. Make sure you drill out holes in the new pan where you'd weld into the frame too. That's how the factory ones were. For the driver side he just made patches where the rust areas werent very big.