Hi Guys,

I have decided to do some maintenance work on my '99 XJ, including hitting the very lightly rusted rockers, Etc with POR 15, I removed the front fender liners and found that the area just above the floor pan is pretty badly rusted, actually through in s few small areas. I'm sure this is due to road salt/grit getting trapped there and rubbing. I pulled up the carpet and insulation, and the inside looks like new. There is a rubber-like material that looks like it was sprayed in, then painted (factory). On top of that was an white insulation pad encased in a plastic bag, followed by a black rubber mat, then the carpet. All that stuff is like new.

Because the rusted through area is above the floor pan, it isn't structural and I am very tempted to just caulk and or pop-rivet a piece of sheet metal in place. I don't own a welder, and am trying to avoid a major restoration. Over all the rig is in really nice shape for Northern Vermont. Any suggestions on how to handle this??

Thanks!

I'd agree that a small amount of rust in that area isn't a huge concern, wire wheeling it clean, encapsulating it then attaching a reinforcement over the top should be fine. As long as you stop the current rust and prevent new...

If its just crusty wire brush or wheel it and por15 over it,If it has rust holes anything smaller then your pinky you can use jb weld or por15 makes por patch use that and por15 over it.If you need to patch it don't pop rivet it you can use panel adhesive and glue it in.Panel adhesive is used in new cars and some in body shops its as strong as a weld.

Thanks for the advice all, gonna patch it with adhesive and aluminum sheet.

Cheers