Replaced front passenger floor pan 95 XJ
 

Replaced the passenger floor pan on my 95 XJ this weekend. It was hot so the first thing I did is made some shade. (My neighbor accused me of being a redneck... lol)

Floor pan #2
 

Yeah it was pretty much gone. Marking the floor pan from the topside.

#3 cleaning everything up
 

Wire brushed everything down, wiped it down with Picklex20. Sprayed the inside of the frame with some black enamel & sprayed all of the edges with weld thru primer & also the top of the frame flanges.

Marked my cut out from the bottom & drill 1/4" holes about every 3.5".

Plug welded the floor pan in. Came out nice & tight.

#4 seat brace & priming
 

Had to fit & weld the seat brace back in & primed everything. Used a bead of high temp RTV on the topside.

Painted everything black. Used seam sealer along all of the bottom edges & undercoated everything. Came out awesome.

I did pull all of the rust pieces off of the matting & sprayed some black over it to seal the rest so I don't end up with the same problem again.

Also pulled the front sway bar & end links & stripped them to bare metal & repainted them. Put new poly main & end link bushing & put everything back on. Stripped & painted the diff's & touched up some on the bottom side & undercoated.

Next thing on the list is a hitch & building a roof rack & steel tube bumpers.

John - Chesapeake, VA

Came out well, Were did you get the drop in pans? O and BTW love the blue color of your rig very nice :yes:

Wow, great pan insert, ya did a really nice job on that. Great lookin rig!

The pan came from Morris 4x4 Center Pompano Beach, FL. The guy I bought the jeep from had bought it but didn't know how to put it in.

Thanks. Get a lot of compliments on the blue. Don't see a lot that color.

This excatly what I need to do.. But both sides and my rust goes back a little further! But now when I get a little money saved I'll know more of what to do! Haha

Floors are such a common trouble spot on these vehicles.

75% of our member or more need to fix or have already fixed.

Mine came with no floors.

Good job, and that is the best looking color on a jeep. I could be partial though

Nice work man! I did mine last fall. I did a full pass side pan and patched the drivers side. Still need to do the cargo floor area in the back by my spare

just plug welds? not a solid weld all around? i'm about to do mine soon and was studying. any help or input is appreciated.

is the plug welding all ya did? or does it get a full weld after the plugs? im about to do the same thing and any input is appreciated. great job BTW

Yes, just plug welded, then go back around it with a seam sealer & re-undercoat the bottom.