Replacing the floorboards on the 93 XJ

[carpenle]

I traded a Subi that I had for a built 1993 XJ (pics and specs to come later), the previous owner had attempted to fix the rusted out floorboards. He decided that thin sheet metal, liquid nails, silicone, and a plastic “for Sale” sign would do the job. He glued it over the rust and left most of the carpet in. Uriah (friend & Partner on the jeep/subi) and I decided to undo all of this mess and make a lasting repair. First we started by removing the seats, carpet, and pad, then we were able just to lift up and remove the entire prior patch. I did not get pics of the prior patch or carpet removal, but here is what we were looking at on the driver side:

http://i379.photobucket.com/albums/oo233/carpenle/1993%20XJ/IMG_20140101_130557_154.jpg (http://s379.photobucket.com/user/carpenle/media/1993%20XJ/IMG_20140101_130557_154.jpg.html)
http://i379.photobucket.com/albums/oo233/carpenle/1993%20XJ/IMG_20140101_130544_572.jpg (http://s379.photobucket.com/user/carpenle/media/1993%20XJ/IMG_20140101_130544_572.jpg.html)


Here is the passenger side:

http://i379.photobucket.com/albums/oo233/carpenle/1993%20XJ/IMG_20140101_125531_157.jpg (http://s379.photobucket.com/user/carpenle/media/1993%20XJ/IMG_20140101_125531_157.jpg.html)
http://i379.photobucket.com/albums/oo233/carpenle/1993%20XJ/IMG_20140101_125537_293.jpg (http://s379.photobucket.com/user/carpenle/media/1993%20XJ/IMG_20140101_125537_293.jpg.html)

We took a wire wheel and a grinder to all of the area to find where the bad metal stopped and where good metal started. Then used a plasma cutter and grinder with a cut off wheel to cut all of the rusted metal away. This is with the rust cut out:
http://i379.photobucket.com/albums/oo233/carpenle/1993%20XJ/IMG_20140101_142505_962.jpg (http://s379.photobucket.com/user/carpenle/media/1993%20XJ/IMG_20140101_142505_962.jpg.html)http://i379.photobucket.com/albums/oo233/carpenle/1993%20XJ/IMG_20140101_145935_492.jpg (http://s379.photobucket.com/user/carpenle/media/1993%20XJ/IMG_20140101_145935_492.jpg.html)

I wire wheeled and cleaned the frame rail, then primed and painted the area where we can not get to once the patch is welded in. We then made a cardboard template and cut a over sized patch panel. This is the panel, with Uriah bending it to fit.
http://i379.photobucket.com/albums/oo233/carpenle/1993%20XJ/IMG_20140101_150008_002.jpg (http://s379.photobucket.com/user/carpenle/media/1993%20XJ/IMG_20140101_150008_002.jpg.html)

This is about as far as we got on new years day, it started to get really cold and snow, so we packed everything up and will finish later.

[Popsgarage]

Not my favorite job for sure. Good luck!

[xaza]

That is the first time I have ever seen what the inside of our frame looks like from top. That is quite a patch.

[carpenle]

That is the first time I have ever seen what the inside of our frame looks like from top. That is quite a patch.

Mine too, it is not very thick. I can see why they need frame stiffeners. This is also why I wanted to get it patched up, pretty important to have the foor to connect the frame and everything.

[Cr33p3r]

oh my the previous owner must not have cared if he went thru the floor or not, good to see you are tackling it the right way to save another ride for a longer life! Keep us posted Levi.

[carpenle]

Keep us posted Levi.

I will, did not get anything done on it this weekend. It was way too cold :frown:

[Cr33p3r]

I know what you mean Levi, that's why I am inside rather than being out in the garage. Plus I don't like welding on thin sheet metal when it's this cold cause it makes it brittle unless you pre warm it.

[carpenle]

So we put a couple more hours into the floor. We hit the edges with some weld through primer:

http://i379.photobucket.com/albums/oo233/carpenle/1993%20XJ/IMG_20140118_122121_514.jpg (http://s379.photobucket.com/user/carpenle/media/1993%20XJ/IMG_20140118_122121_514.jpg.html)

Drilled our patch along the frame to spot weld.

http://i379.photobucket.com/albums/oo233/carpenle/1993%20XJ/IMG_20140118_130838_597.jpg (http://s379.photobucket.com/user/carpenle/media/1993%20XJ/IMG_20140118_130838_597.jpg.html)

Here is how the passenger fits.

http://i379.photobucket.com/albums/oo233/carpenle/1993%20XJ/IMG_20140118_131001_923.jpg (http://s379.photobucket.com/user/carpenle/media/1993%20XJ/IMG_20140118_131001_923.jpg.html)

[carpenle]

Then went to work burning it in.

http://i379.photobucket.com/albums/oo233/carpenle/1993%20XJ/IMG_20140118_140609_004.jpg (http://s379.photobucket.com/user/carpenle/media/1993%20XJ/IMG_20140118_140609_004.jpg.html)http://i379.photobucket.com/albums/oo233/carpenle/1993%20XJ/IMG_20140118_135520_648.jpg (http://s379.photobucket.com/user/carpenle/media/1993%20XJ/IMG_20140118_135520_648.jpg.html)http://i379.photobucket.com/albums/oo233/carpenle/1993%20XJ/IMG_20140118_140816_668.jpg (http://s379.photobucket.com/user/carpenle/media/1993%20XJ/IMG_20140118_140816_668.jpg.html)http://i379.photobucket.com/albums/oo233/carpenle/1993%20XJ/IMG_20140118_140617_840.jpg (http://s379.photobucket.com/user/carpenle/media/1993%20XJ/IMG_20140118_140617_840.jpg.html)

[carpenle]

started on the driver side patch

http://i379.photobucket.com/albums/oo233/carpenle/1993%20XJ/IMG_20140118_120359_885.jpg (http://s379.photobucket.com/user/carpenle/media/1993%20XJ/IMG_20140118_120359_885.jpg.html)http://i379.photobucket.com/albums/oo233/carpenle/1993%20XJ/IMG_20140118_130315_019.jpg (http://s379.photobucket.com/user/carpenle/media/1993%20XJ/IMG_20140118_130315_019.jpg.html)

Drilled the spot welds and hit all of the edges with weld through primer.

http://i379.photobucket.com/albums/oo233/carpenle/1993%20XJ/IMG_20140118_142121_335.jpg (http://s379.photobucket.com/user/carpenle/media/1993%20XJ/IMG_20140118_142121_335.jpg.html)

That is as far as we got, it got cold and windy. Came down with a cold, so this project has been sitting.

[Brad]

Lookin good Levi! :thumb:

[carpenle]

So we got a nice day on Sat. to work on this project. We welded in the driver side floor.http://i379.photobucket.com/albums/oo233/carpenle/1993%20XJ/IMG_20140329_153703_440.jpg (http://s379.photobucket.com/user/carpenle/media/1993%20XJ/IMG_20140329_153703_440.jpg.html)

Then we cleaned and wire brushed everything. Hit all of the seams with seam sealer

http://i379.photobucket.com/albums/oo233/carpenle/1993%20XJ/IMG_20140329_153537_700.jpg (http://s379.photobucket.com/user/carpenle/media/1993%20XJ/IMG_20140329_153537_700.jpg.html)http://i379.photobucket.com/albums/oo233/carpenle/1993%20XJ/IMG_20140329_174208_008.jpg (http://s379.photobucket.com/user/carpenle/media/1993%20XJ/IMG_20140329_174208_008.jpg.html)

[carpenle]

Seam sealed the under side

http://i379.photobucket.com/albums/oo233/carpenle/1993%20XJ/IMG_20140329_174304_102.jpg (http://s379.photobucket.com/user/carpenle/media/1993%20XJ/IMG_20140329_174304_102.jpg.html)http://i379.photobucket.com/albums/oo233/carpenle/1993%20XJ/IMG_20140329_174310_233.jpg (http://s379.photobucket.com/user/carpenle/media/1993%20XJ/IMG_20140329_174310_233.jpg.html)

Then hit the whole floor with liner

http://i379.photobucket.com/albums/oo233/carpenle/1993%20XJ/IMG_20140329_191035_764.jpg (http://s379.photobucket.com/user/carpenle/media/1993%20XJ/IMG_20140329_191035_764.jpg.html)http://i379.photobucket.com/albums/oo233/carpenle/1993%20XJ/IMG_20140329_191057_590.jpg (http://s379.photobucket.com/user/carpenle/media/1993%20XJ/IMG_20140329_191057_590.jpg.html)

[carpenle]

Glad this phase of the project is done. Waiting for good weather was the hardest part. The floor is a major part to the xj uni body, so it is good it all fixed.

[Sinister68]

Looks good I unfortunately have to do the same thing on the passenger side of my xj. Bought the xj and didn't think anything of it. Went wheeling and went through aretty good water hole and lone behold my floorboard was covered with mud when I went to clean it out. Pulled the mat up and there was a pretty big whole with piece of metal laying over held down by the mat.

[carpenle]

there was a pretty big whole with piece of metal laying over held down by the mat.

Hopfully it is not to big or as bad as mine. It would have been a lot easier if it was just the flat part that was rusted, but mine had to be formed to fit. I would cut it out as soon as possible, so it does not keep growing.

[xaza]

Looks sweet, nice job.