My new to my daughter 1997 XJ with absolutely no rust. I found water on the passenger side front floorboard. From what I understand it's coming from the cowl panel. This past week I removed all the seats and the carpet to find a rust hole. I cut it out and replaced the whole section with 18ga steel. Welding was a bit tricky but I just pushed the weld from the new piece to the stock floorboard. Took some time but I believe the end result is pretty good I think.

 

I’ll be diving into to explore mine soon. Your work looks great. Was your carpet padding glued down?

 

Looks good. Take care of all that pitted metal while youre there. Aside from that, thats a clean floor. Did you use a weld thru primer, or any sealers?

 

Thanks. No it did not appear to be glued down anywhere.

 

fb97xj1 Thanks I plan on taking care of all of it. I did a weld through primer on the bottom side. After I am finished with all the welding the undercarriage will be cleaned and a heavy coat of undercoating will be sprayed on. The interior will be completely sanded and I plan to "Herculiner" the floorboard front to rear.