okay, so before I get flamed. the jeep is very solid on the outside, rockers and pinch seams solid. Floors were shot, so I decided to replace them.
I dont have alot of pics at the moment, because I wasnt going to do this thread.
Basically, remove your stock carpet and padding, because its a sponge, and throw it away forever.
To do this, you remove the seats, and center consoul.
Next grab a big shop vacuum, and start sucking up all the loose crap.
this isnt the jeep i started with, but this is how ALOT of xjs look without the carpet, when they have rust.
Again THIS IS NOT THE JEEP IM WORKING ON, its an old one i had. the one im working on has better floors, and body in general, i just didnt take progress pics, and happened to have these FOR REFERENCE.
basically what your rear floor probabaly looks like.
front floor wells
so start cutting that rust out,
now, you have to clean all that out, get a welding hammer/pick and knock all the loose rust off the channels, get all the old floor off the top of the unibody rails, there are also spot welds you will have to grind down flush.
all this was done with cut off wheels on a grinder, a grinder, and a hammer / shop vacuum.
Again that wasnt the jeep im working on.
Now, onto the jeep im working on, once everything was cut outt, fully cleaned and wire wheeled. i decided to paint the u channels from the inside out. I'm using rustoleum red primer, I will be going over this all with a second coat, and then with rustoleum paint before the new floors go.
Now to all the nay sayers, who are like "oh go buy another jeep blah blah.
pre 96 xjs are high mile junk everywhere, and id rather not spend all my money replacing driveline parts, when floors are cheap and easy.
I'm going to take the time to use 3/16th plate over where the leafs mount front and back, and by tieing that all in, making the mounts straonger than they ever were.
I'll post more pics, and hopefully when im done this will serve as a very nice how too for people.
Its not as bad as it looks, its not that much work if you can weld, and cut metal.
For reference, all the metal i bought for the floor
8 sq ft of 18 guage steel - 60$
i also bought 15' of 3/16th x 5'' plate for 45$ (im building recovery bumpers aswell)
so if you figure in 100$ worth of materials + time, not counting paint. You'll realize this is worth it on a budget.