The front left and right floor pans are rusted out almost completely. it is mostly the low, flat surfaces where moisture in the carpet clung to the metal. I have some holes in other spots and near the back that I plan on patching with sheet metal and using a good seam sealer/under coating to protect.

Is it easy with enough time to cut/bend sheet metal to fix gaps over a foot long, or is it worth the extra money to buy a whole new pan for the worst spots?

I plan on pop riveting and sealing, no welding. My rockers are completely rusted as well as that pinch seam under, but all the metal not at the lowest points or on the rocker is in good shape.

Fred Flintstone would have no issue driving my XJ, and that is before I have cut out the rust that hasn't already fallen off.

 

I used some old doors to patch up my 96. I used stainless steel rivets and tiger caulk to seal it.

 

I like that! better than the license plate patch I see used so much. I don't have spare doors laying around so sheet may be cheaper.

 

I used metal from Home Depot 1/16" thick.

 

I had some old XJ doors sitting around, figured I could put them to good use and patch my floor with recycled XJ parts.

 

how does home depot sell it? Like by the square foot or as a product used in another application that you adapted for the XJ lol

 

Nice! You just made me realize I could use my wrecked 91s hood to patch the floor in my 99. Except I'm gonna weld it up.

Thanks.

 

I got a huge shee of 16 gauge sheet metal for less than $40. 4'x5'.

Using doors and hoods?

 

It was the same thickness as what I cut out. The doors were trashed, bashed into a tree. I wouldn't use a good part for something like that.

 

Another '96 with no floors. I wonder what it is about that year?

Another source of good, cheap or free metal is side panels on old washer/dryers. Normally has a porcelain paint finish too that prevents rust.

pro tip: Don't use your wife's.

 

To each his own, I guess.

 

Its not just the 96s. Its all XJs. Not sure if the metal was just real thin or what.

My floors on my 87 didnt even exist anymore.

 

It was a forest service XJ. It had surface rust everywhere!

 

Yeah, you're right. Just seems the last few "where's my floor" posts have been '96's, lol. Maybe they're all rotting at about the same speed and the 96's are now up to bat.

 

Dude, Where's my floor?