Northern Utah BS thread
Senior Member
Joined: Oct 2009
Posts: 502
Likes: 0
From: Redlands, CA
Year: 1992
Model: Cherokee
Engine: 4.0L I6
So I was under my XJ the other day greasing and tweaking stuff and I noticed that a huge section of my passenger side floor board is completely rusted through. It just looked like the undercoating was peeling, but when I started poking at it I realized I was poking at my carpet (from underneath)!
I thought there would be some rust cause last june when it rained like a b!tch my carpet got wet on that side. I wasn't sure if it was coming from under or behind my firewall, but now I know!
It really sucks cause it only has 120K. So I'm starting to weigh my options. I could, of course, replace the floor plan, but I dont have a welder or any way to bend sheetmetal very well. Plus, I don't want to "bedliner" the inside and don't want to replace the carpet. I could buy a "shell" and throw my drivetrain and lift/tires on it, but then I'd be without a daily driver for a few days. Or I could buy a "fixer" and start a whole new project.
What to do, what to do?!?
I thought there would be some rust cause last june when it rained like a b!tch my carpet got wet on that side. I wasn't sure if it was coming from under or behind my firewall, but now I know!
It really sucks cause it only has 120K. So I'm starting to weigh my options. I could, of course, replace the floor plan, but I dont have a welder or any way to bend sheetmetal very well. Plus, I don't want to "bedliner" the inside and don't want to replace the carpet. I could buy a "shell" and throw my drivetrain and lift/tires on it, but then I'd be without a daily driver for a few days. Or I could buy a "fixer" and start a whole new project.
What to do, what to do?!?
Senior Member
Joined: Oct 2009
Posts: 859
Likes: 0
From: Hyrum,UT
Year: 2001
Model: Cherokee
Engine: 1-6 4.0
welcome to utard!! where are you at i have all the body tools and a welder i could help you but you would have to come to hyrum but we could get it done. let me know.
Thread Starter
CF Veteran

Joined: Sep 2009
Posts: 3,612
Likes: 0
From: West Valley
Year: 1998
Model: Cherokee (XJ)
Engine: 4.0
Ouch. Hey Rat, wish I'd have been on here sooner and I would have steered you away from Crusty's. AJ's Armor and JCR Offroad have way better products at way better prices. Hope this doesn't create buyers remorse... 
AJ's are $300 shipped;
http://www.ajsoffroadarmor.net/XJ_SuperRails.html
JCR's are also $300 shipped;
http://www.jcroffroad.com/Merchant2/...egory_Code=XJS
Both excellent companies with stellar customer service and they treat the XJ guys right. Rusty's... well let's just say I would STAY AWAY from Rusty's.

AJ's are $300 shipped;
http://www.ajsoffroadarmor.net/XJ_SuperRails.html
JCR's are also $300 shipped;
http://www.jcroffroad.com/Merchant2/...egory_Code=XJS
Both excellent companies with stellar customer service and they treat the XJ guys right. Rusty's... well let's just say I would STAY AWAY from Rusty's.
Last edited by Desert Rat; Feb 18, 2010 at 06:56 PM.
Thread Starter
CF Veteran

Joined: Sep 2009
Posts: 3,612
Likes: 0
From: West Valley
Year: 1998
Model: Cherokee (XJ)
Engine: 4.0
Thread Starter
CF Veteran

Joined: Sep 2009
Posts: 3,612
Likes: 0
From: West Valley
Year: 1998
Model: Cherokee (XJ)
Engine: 4.0
So I was under my XJ the other day greasing and tweaking stuff and I noticed that a huge section of my passenger side floor board is completely rusted through. It just looked like the undercoating was peeling, but when I started poking at it I realized I was poking at my carpet (from underneath)!
I thought there would be some rust cause last june when it rained like a b!tch my carpet got wet on that side. I wasn't sure if it was coming from under or behind my firewall, but now I know!
It really sucks cause it only has 120K. So I'm starting to weigh my options. I could, of course, replace the floor plan, but I dont have a welder or any way to bend sheetmetal very well. Plus, I don't want to "bedliner" the inside and don't want to replace the carpet. I could buy a "shell" and throw my drivetrain and lift/tires on it, but then I'd be without a daily driver for a few days. Or I could buy a "fixer" and start a whole new project.
What to do, what to do?!?
I thought there would be some rust cause last june when it rained like a b!tch my carpet got wet on that side. I wasn't sure if it was coming from under or behind my firewall, but now I know!
It really sucks cause it only has 120K. So I'm starting to weigh my options. I could, of course, replace the floor plan, but I dont have a welder or any way to bend sheetmetal very well. Plus, I don't want to "bedliner" the inside and don't want to replace the carpet. I could buy a "shell" and throw my drivetrain and lift/tires on it, but then I'd be without a daily driver for a few days. Or I could buy a "fixer" and start a whole new project.
What to do, what to do?!?
CF Veteran
Joined: May 2009
Posts: 6,328
Likes: 1
From: SLC, UT
Year: 1989 2 door
Model: Cherokee
Engine: 4.0
Ya aaron I wouldn't want to drop the whole rig, cause of 1 side being rusted through! Although I'm sure you're scared to look, but you might want to pull all the carpet... Its a damn shame!!!
Thread Starter
CF Veteran

Joined: Sep 2009
Posts: 3,612
Likes: 0
From: West Valley
Year: 1998
Model: Cherokee (XJ)
Engine: 4.0
Senior Member
Joined: Oct 2009
Posts: 859
Likes: 0
From: Hyrum,UT
Year: 2001
Model: Cherokee
Engine: 1-6 4.0
so i started a new front bumper the other day it is not done yet. i still have to do some plating and braceing for the unibody but here is what i got so far. it is made out of 5 inch channel and 1/8 flat plate and when the funds come in i will make it to hold a winch.
here is the welder i use.


here is some of my welds still learning but i think it will hold just fine.

so what do you think? when it is all done this week end i will post pics of it all done and on the jeep.
here is the welder i use.

here is some of my welds still learning but i think it will hold just fine.
so what do you think? when it is all done this week end i will post pics of it all done and on the jeep.
Senior Member
Joined: Oct 2009
Posts: 859
Likes: 0
From: Hyrum,UT
Year: 2001
Model: Cherokee
Engine: 1-6 4.0
it is a 120v and 140 it will weld up to 1/4 with out gas and 5/16 with gas on a low setting. i like it i got it from home depot on sale it was returned but worked just fine for like $250. i have made slidders and a couple of bumpers and i started a off road camping trailer last summer. so i have got my money worth out of it.
Member
Joined: Apr 2009
Posts: 152
Likes: 0
Year: 1999
Model: Cherokee
Engine: 4.0-liter 190-horsepower inline six


