My 92 XJ's bottom floor pan ( for lack of a better word) along the top of the exhaust system from the muffler back to the rear is slowly rotting . My guess is due to the heat/cold cycling of the exhaust sys and age, etc.

What are any techniques or methods to replace it ?
Dimensions roughly are 12" wide by 3 ft long area.

 

Where I got my floor pans and rocker panels from http://c2cfabrication.com/wp-content...218&syear=1992

Here are some before and after pics of my truck https://www.cherokeeforum.com/f46/my...ebuild-111932/

 

I got the fronts from the same place. Haven't had time to put them in yet. I'm just using scrap 18ga steel to patch the cargo area, as time permits. They sell the whole panel for the cargo area, but most of my sheet metal back there was ok.

Its a pain in the a$$, and very time consuming, plus I've had to re-teach myself how to weld. My grandfather taught me many years ago, but haven't I touched a welder since he died in the 80's. If you've got some basic welding skills and lots of time, you shouldn't have a problem.

Just make sure you have all the rust cut out and the rest of it ground down to good metal where you're going to weld. And don't overlap your repair panel with the original to much... just enough to get a good weld and to hold the integrity. If you throw the new panel right on top of the old, you're just creating a breeding ground for moisture and rust, and your repair won't last long at all.

 

Got a nice MIG welder, plenty of grinders, cutting tools etc and indoor bay to do the work. Looks like the hardest part is removing seats carpet ?
Am pretty savvy with the metal work dept.

 

I bought everything from Rock Auto, including rocker panels. They fit good with only minimum grinding needed. I had to buy a piece of sheet steel to fix trunk pan. You'll be an expert welder when you get done.