In this thread I am merrily posting how I put new floor pans on both sides of the front half of the floor. This is after I replaced the rocker panel backing plate; and the the outer rocker panel where replaced.

Note: The order in which you do this is important as you are dealing with the structural integrity of the jeep. But do not let this intimidate you as it is not as hard are you think as long as you use care.

To recap I had removed all the seam sealer along the "lip" where the backer and the floor pan meet to expose the tack welds.

I then drilled them out at each point the everything was mated together via tack welds, then I chiseled them out using a hammer and a special chisel for the purpose of popping welds. NOTE: you can use an air hammer but can cause more damage to parts you dont want to remove.

Then I used 3m panel bond, to glue the backer plate and the rocker panel back together. and then welded everything back together.



this photo is a really good example of how it is all tack welded together


Note: if your floor pan is just what needs to be done then you do not have to do this step.

fitment of the floor pan around the bell housing is important. I cut 1" more than the traced line of the new pan. leaving some extra good metal to cut as needed. I also cut the backside where the old pan meets the new.

here is the view underneath. it is not nessicary to weld down here bit is important to place


n this photo you can see where I needed to add some additional metal to the floor. I then put some POR15 on the floor and seam sealed over top. it is very important to seam seal the areas where welding occurred.



you can now clearly see how where the former floor pan and the new floor pan meet in this photo