Very nice!

Something like my It-Can't-Be-Done replacement of a badly rusted rear frame rail with a donor. I put a 94 part into my 97.

Then totaled it a year later!

 

With spotwelds cut, all major uniframe mating surfaces are exposed for new welds (See orange boxes). The floor issue will be next after the rocker panel/pillar assembly is secure.

 

2x6 rockers

 

Man, that is heavy-duty.......What year is that?

 

Great job. Nice work!

I'm confident the door pillar could have been pulled out, but I get why you replaced it ...no harm done, and you'll guarantee perfect door fit.

This is a good thread to inspire guys who want to keep good (but wrecked) Jeeps on the road.

 

You got it.....The one on mine was completely intact, but I didn't want to separate the salvage pillar from its rocker panel.

I will also start cutting rusted floor away to accommodate the new front and back (drivers side floor pans).

 

If you want do declutter your engine bay, now might be a good time to install a 1997-2001 windshield washer bottle. On the 1997-2001 XJ, the windshield washer bottle fits into the drivers / left front fender.

 

Ready for welding......How good are your plug welds?

 

Who needs a $20,000.00 autoframe rack when you have a chain, turnbuckle......and a heavy vehicle with a trailer hitch?.............
only needed to come out not more that 1/2-3/4".....

 

New floor pans in. Mated to the strip of floor (left) which was part of the rocker panel/B-pillar assembly welded in. Ist coat of sealer applied. This part of the job has been posted by many others on YouTube and on JeepForum

 

That's looking great. Only if my floors looked like that. One day...

 

The black plastic ~1.5" plug next to the drain hole (lower right) is a 3D print. 2 coats of sealer/one coat of 'bright white' on gray primer.

 

Yup!!
Here are some of the results........

 

Really nice work. Congratulations.

Question on the floor pans. Are those spot welds or rivets? They kind of look like rivets. I only ask because I have to do my floors too and I have been debating spot welds or rivets.

Thanks.

 

Thanks!

Spot welds
Hobart 140 Mig welder
75/25 argon/CO2 gas

The sheet to sheet spot welds and beads used a lower heat setting (2); the sheet to frame rail welds were actually plug welds, higher heat setting (3) since the frame rails are thicker metal.
I'm doing my rear deck when it gets warmer; I'm kicking around the idea of using steel rivets; but I am addicted to my Hobart.