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)

 

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

 

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.

 

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

 

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.