WOW... I dont know if i would have the time to do that big of a project. But it sure is coming out good.

 

Since, this thread is so old, I don't think I'm threadjacking. :-)

I had a jammed up door, which I finally got loose. Beneath it, I found that the rust from the rocker has made it's way up into the door seams. I need to pull the carpet, but would you replace this in the same way you replaced the floor? I'm thinking I can cut the lower rocker panels out, replace with a 2x6 of steel, then bend some sheet metal to fit these curves, then weld it and clean it up with filler and some bed liner.

I also found an exact XJ in a yard nearby that said I could go in and cut the chunk out that I need. - Is that feasible or even recommended? I'm trying to throw some R&D time at this XJ as it's my first, so I can transplant everything I build for it over to another one in a year when I have some spare money to buy a cleaner one.

Mechanically, this one is mint with 143k on it and everything works as it should. I'd really rather not have to go out and get another one, as we have a trip to Colorado planned for September and were hoping to have this thing ready to go.

 

My lord! Make sure you check around the frame with a screwdriver before goin any further. With rust it's not about what you can see but what you can't see