I recently pulled up the rear carpet in my 1995 Jeep Cherokee Sport to
get access to a set of stripped & snapped shock bolts and mountings
(whole other post!). What I found was a soaked carpet and three
penny-sized holes, strait in a line, where water was deflecting off
the muffler and a support beam. A smiliar set would have formed in a
parallel to line to these holes had it not been for the support on the
passenger side being in contact with the bed. The metal on top of
that strut had not rusted through completely and looked like a skin
boil.

It looks like when they undercoated, these areas were out of the
line-of-sight of the nosle and did not recieve a good coating, if any
at all. If that isn't the case, I can see how the water would have
over time worn away at those specific areas.

Wired brushed the rust off, fiberglassed, primed, and painted all the
rust spots I could find(very minor)--but the question remains, where
else will the rust be? Has anyone else noticed a pattern of rust in
the 1995 sports?

The next project is to do the front half...

 

I've gotten two xj's in the last month, a 89 and a 96. the floor on the
driver's side is gone with a smaller hole above where the muffler is. The 96
being newer only had one dime sized hole but blistered areas in other places,
To answere your question, every place there is a seam or a plate welded on
underneath, you'll have problems. You may be shocked when you remove the seats,
console and carpet!

JoBo

"Dustin Grimes" <stormswynd@hotmail.com> wrote in message
news:26562499.0408111226.6fef462c@posting.google.c om...
> I recently pulled up the rear carpet in my 1995 Jeep Cherokee Sport to
> get access to a set of stripped & snapped shock bolts and mountings
> (whole other post!). What I found was a soaked carpet and three
> penny-sized holes, strait in a line, where water was deflecting off
> the muffler and a support beam. A smiliar set would have formed in a
> parallel to line to these holes had it not been for the support on the
> passenger side being in contact with the bed. The metal on top of
> that strut had not rusted through completely and looked like a skin
> boil.
>
> It looks like when they undercoated, these areas were out of the
> line-of-sight of the nosle and did not recieve a good coating, if any
> at all. If that isn't the case, I can see how the water would have
> over time worn away at those specific areas.
>
> Wired brushed the rust off, fiberglassed, primed, and painted all the
> rust spots I could find(very minor)--but the question remains, where
> else will the rust be? Has anyone else noticed a pattern of rust in
> the 1995 sports?
>
> The next project is to do the front half...

 

I've gotten two xj's in the last month, a 89 and a 96. the floor on the
driver's side is gone with a smaller hole above where the muffler is. The 96
being newer only had one dime sized hole but blistered areas in other places,
To answere your question, every place there is a seam or a plate welded on
underneath, you'll have problems. You may be shocked when you remove the seats,
console and carpet!

JoBo

"Dustin Grimes" <stormswynd@hotmail.com> wrote in message
news:26562499.0408111226.6fef462c@posting.google.c om...
> I recently pulled up the rear carpet in my 1995 Jeep Cherokee Sport to
> get access to a set of stripped & snapped shock bolts and mountings
> (whole other post!). What I found was a soaked carpet and three
> penny-sized holes, strait in a line, where water was deflecting off
> the muffler and a support beam. A smiliar set would have formed in a
> parallel to line to these holes had it not been for the support on the
> passenger side being in contact with the bed. The metal on top of
> that strut had not rusted through completely and looked like a skin
> boil.
>
> It looks like when they undercoated, these areas were out of the
> line-of-sight of the nosle and did not recieve a good coating, if any
> at all. If that isn't the case, I can see how the water would have
> over time worn away at those specific areas.
>
> Wired brushed the rust off, fiberglassed, primed, and painted all the
> rust spots I could find(very minor)--but the question remains, where
> else will the rust be? Has anyone else noticed a pattern of rust in
> the 1995 sports?
>
> The next project is to do the front half...

 

I've gotten two xj's in the last month, a 89 and a 96. the floor on the
driver's side is gone with a smaller hole above where the muffler is. The 96
being newer only had one dime sized hole but blistered areas in other places,
To answere your question, every place there is a seam or a plate welded on
underneath, you'll have problems. You may be shocked when you remove the seats,
console and carpet!

JoBo

"Dustin Grimes" <stormswynd@hotmail.com> wrote in message
news:26562499.0408111226.6fef462c@posting.google.c om...
> I recently pulled up the rear carpet in my 1995 Jeep Cherokee Sport to
> get access to a set of stripped & snapped shock bolts and mountings
> (whole other post!). What I found was a soaked carpet and three
> penny-sized holes, strait in a line, where water was deflecting off
> the muffler and a support beam. A smiliar set would have formed in a
> parallel to line to these holes had it not been for the support on the
> passenger side being in contact with the bed. The metal on top of
> that strut had not rusted through completely and looked like a skin
> boil.
>
> It looks like when they undercoated, these areas were out of the
> line-of-sight of the nosle and did not recieve a good coating, if any
> at all. If that isn't the case, I can see how the water would have
> over time worn away at those specific areas.
>
> Wired brushed the rust off, fiberglassed, primed, and painted all the
> rust spots I could find(very minor)--but the question remains, where
> else will the rust be? Has anyone else noticed a pattern of rust in
> the 1995 sports?
>
> The next project is to do the front half...

 

I've gotten two xj's in the last month, a 89 and a 96. the floor on the
driver's side is gone with a smaller hole above where the muffler is. The 96
being newer only had one dime sized hole but blistered areas in other places,
To answere your question, every place there is a seam or a plate welded on
underneath, you'll have problems. You may be shocked when you remove the seats,
console and carpet!

JoBo

"Dustin Grimes" <stormswynd@hotmail.com> wrote in message
news:26562499.0408111226.6fef462c@posting.google.c om...
> I recently pulled up the rear carpet in my 1995 Jeep Cherokee Sport to
> get access to a set of stripped & snapped shock bolts and mountings
> (whole other post!). What I found was a soaked carpet and three
> penny-sized holes, strait in a line, where water was deflecting off
> the muffler and a support beam. A smiliar set would have formed in a
> parallel to line to these holes had it not been for the support on the
> passenger side being in contact with the bed. The metal on top of
> that strut had not rusted through completely and looked like a skin
> boil.
>
> It looks like when they undercoated, these areas were out of the
> line-of-sight of the nosle and did not recieve a good coating, if any
> at all. If that isn't the case, I can see how the water would have
> over time worn away at those specific areas.
>
> Wired brushed the rust off, fiberglassed, primed, and painted all the
> rust spots I could find(very minor)--but the question remains, where
> else will the rust be? Has anyone else noticed a pattern of rust in
> the 1995 sports?
>
> The next project is to do the front half...