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Topic: Hole in the floor

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ChevelleSSLS6
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Hole in the floor
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My XJ has a small (nickel size) rust hole in the back of the floor (I can feel carpet up in the hole).  What should I do about it?  I was thinking cut away rusty part and weld in a patch... and pulling the carpet and putting down truck bedliner stuff.

My questions...
1. has anyone done this with the DIY truck bedliner stuff?  Results?
2. how much of the interior needs taken apart to pull the carpet?
3. Hopefully this will prevent further rusting, and keep the snow that gets past the floormat in the winter from sitting in the carpet, rusting the floor.

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dstaub
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i am actually in the process of doing the exact same thing on the floor board of the drivers side feet area.  i've got a hole about an inch across.  i will be cutting out a patch, welding in new steel, and then probably ripping out the carpet in the front (my xj is a 2 door) and bedlining it with Herculiner roll-on.  that stuff works great!!! i highly recommend it!

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SCORE!: 1996 Cherokee Sport, bone stock, excellent condition, one owner, with currently 47,000 ORIGINAL miles!!
CURRENTLY:  2001 Cherokee Limited 4-dr, 33" Uniroyal Liberator A/Ts, 6-8" well built custom lift (sorry, i haven't measured yet).

SOLD: Project Rig: 87 Cherokee Pioneer 4dr.  bone stock now.  coming soon: 3" budget lift, go completely doorless and chop the rear cargo area out.

SOLD:  '98 Cherokee Sport 2dr, 3" SkyJacker w/ 2" budget boost, 31" Truxxus meats, Protofab off-road bumpers & rock rails, KC Highlights
threeEs99
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I had the same problem up front passanger side floor. I did exactly that. Remove seats, all related trim, seat belts, center councle, and finally all drain plugs.
Inspect entier floor for other problem areas. Mine had misc. screw holes so I drilled them out clean and used pop rivits to fill them. Cut out rust holes and remove all surface rust and loose paint. Wipe entire floor down with aceitone (Autozone), fix holes. Now comes hard part. Their are through out the interior adhesive heat sheilds. I removed mine and let me say this part of job took me about five hours. It looks cleaner but was a lot of work. A heat gun is the tool to have for this. Also removed padding on floor in cargo area. Same manner.
You dont have to but at this point I removed door seals and preped rockers and door sills in same maner. Also removed plastic door sill scuff plates and welded screw holes up (they are actually oblong shaped so pop rivits wouldnt work). Ground them flat and scuff sanded sills,rockers, and pinch weld for door seal.
There is a ground for tail lights and interior lighting under pass. seat. THIS HAS TO BE PUT BACK.!!
Trust me, leave bolt for it in hole after you disconnect it, and mask it off. Dont get liner on it.
Depending on brand you use, the kit should come with a scuff pad use this to scuff entire floor. I used the gallon kit of hurculiner (Autozone). It dose two coats, floor, and rockers.
Just follow install directions, this is the easy part.
Tip: Rember to reinstall all grounds.
Buy some dupli color liner in spray can. I sprayed it under seat brkts. Cant get them with brush
Aceitone is you best friend ( Hurculiner insists on its use)

Dupilcolor also makes kit, my friend use it on his Bronco. IT IS NOT SKID RESISTANT.
Hurculiner is and your feet stay in place when driving.

Hope this helps.

-- Edited by threeEs99 at 08:46, 2008-03-05

-- Edited by threeEs99 at 08:46, 2008-03-05

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aci4369
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That is some good info TheeEs.  You don't happen to have pics to help with that write up.  I am uncertain what the adheasive heat shields are. hmm

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threeEs99
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No I didnt take pics, but the heat shields look like alum. stickers some cover factory uni-body plugs. The plugs will not come out unless you pry them out. One of mine actually rusted out. In my case I just cut a piece of metal and repaired it.

The adhesive looks like a black tar and makes a huge mess if you try to wire wheel it off.
Best bet is to use the heat gun with a flat bar. I also tried to use the tip with a scraper on the gun itself. Dont try it unless you are a firebug.

The pad in cargo area is the same stuff w/o alum. backing and is much easier to remove.

If you take your carpet up you will see them. Sorry I've never thought to take pics.of my projects. Maybe I'll do so on next one or if you want to drive to Redford I'll give a hand to anyone wanting to do this.

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04 wj (w/3 car seats too)
DD duty for the lady  
aci4369
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Hmmm I think I know what you are talking about.  I have thought about removing the carpet in the XJ before, but isn't it a lot louder without the carpet.  If I take the carpet out and it is even louder the wife will prolly like it less and that is a bad thing.  Gotta keep her happy with it or she will make me get rid of it!!! haha

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'99 XJ, 5.5" lift, 33" MT's
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threeEs99
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Yes is dose get louder. Also hotter from exhaust and trans.
I dont know about yours but my carpet smelt bad, that could offset wifes opinion about noise.

-- Edited by threeEs99 at 20:20, 2008-03-05

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rust bucket, DD, 3 car seats
04 wj (w/3 car seats too)
DD duty for the lady  
dstaub
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i'm with threeEs99.  it will get louder, but on the other hand my carpet smelled musty as well and therefore i didn't care about the added noise.  if you Herculiner the floor it will cut down on some noise, since it is a dense rubberized liner.  and also, another thing to cut on noise is to use some rubberized spray on (or roll-on) underbody coating on the underbody (obviously). 



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SCORE!: 1996 Cherokee Sport, bone stock, excellent condition, one owner, with currently 47,000 ORIGINAL miles!!
CURRENTLY:  2001 Cherokee Limited 4-dr, 33" Uniroyal Liberator A/Ts, 6-8" well built custom lift (sorry, i haven't measured yet).

SOLD: Project Rig: 87 Cherokee Pioneer 4dr.  bone stock now.  coming soon: 3" budget lift, go completely doorless and chop the rear cargo area out.

SOLD:  '98 Cherokee Sport 2dr, 3" SkyJacker w/ 2" budget boost, 31" Truxxus meats, Protofab off-road bumpers & rock rails, KC Highlights
threeEs99
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Dans rite, I forgot to do this at the time. I'll add it to my list of summer projects.

Thought of this while working today. For about a week the smell of hurculiner is really strong. I suggest doing it in the warmer season and keep people with sensitive sense of smell away.

-- Edited by threeEs99 at 20:29, 2008-03-05

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99 sport.
rust bucket, DD, 3 car seats
04 wj (w/3 car seats too)
DD duty for the lady  
dstaub
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Posts: 523
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LOL yeah herculiner has a VERY POTENT odor to it!  don't put it on with the garage all closed up as i did.  on came the headache real quick!!!  ventilate, ventilate, ventilate!

__________________
SCORE!: 1996 Cherokee Sport, bone stock, excellent condition, one owner, with currently 47,000 ORIGINAL miles!!
CURRENTLY:  2001 Cherokee Limited 4-dr, 33" Uniroyal Liberator A/Ts, 6-8" well built custom lift (sorry, i haven't measured yet).

SOLD: Project Rig: 87 Cherokee Pioneer 4dr.  bone stock now.  coming soon: 3" budget lift, go completely doorless and chop the rear cargo area out.

SOLD:  '98 Cherokee Sport 2dr, 3" SkyJacker w/ 2" budget boost, 31" Truxxus meats, Protofab off-road bumpers & rock rails, KC Highlights
 
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