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:
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Here is the passenger side:
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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:
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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.
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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.