Re: XJ floorboard holes
 

just did mine a few years ago.
Be carefull as you clean/ grind the areas mine was a disaster!!!!!!!!!! More
rust than first thought!!
Get 20G steel from local sheet metal place, rent , borrow, or (this is a
good excuse for a MIG welder purchase, how I justified mine to my wife).
Make cardboard templates and then cut the sheet metal and fit into place and
spot weld in best you can (tough to weld all of the area but possible). Get
some SEAM SEALER and go over welds and seams top and bottom. Get some POR15
and brush on top and bottom after sealer dries and good to go.
For some reason the passenger rust out bad compared to driver with moisture
still present, check tube that extends from door to body with the wires in
it and make sure no water gets in behind cowl.
Good time to remove all the carpet and padding and give a good cleaning.
Watch out if using cutting wheel and or grinding that the sparks damage roof
liner and or any glass like the windshield doors etc...

Good luck about 3 beers *** skill level..


"philthy" <dbrider@cac.net> wrote in message
news:46582D39.83D1304D@cac.net...
> be carefull since the floor metal is attached to the frame rails and that
> is what makes it survive a crash so include reinfocing that alongwith the
> holes
>
> Grumman-581 wrote:
>
>> As I mentioned in a previous post, I have a couple of holes to repair
>> in the passenger side floorboard of my XJ... What is the best way to
>> repair this?
>>
>> 1. Weld replacement sheet metal over the holes.
>> 2. Rivet replacement sheet metal over the holes and fiberglass around
>> the edges so that it will be air tight.
>> 3. Forget about metal and just fiberglass the holes.
>>
>> The larger hole is over the muffler, so I'm not sure if the
>> fiberglass-only method would withstand the heat...
>

Re: XJ floorboard holes
 

On Sun, 3 Jun 2007 17:15:10 -0400, "TF" <flannery16@insightbb.com>
wrote:

> Get 20G steel from local sheet metal place

Thanks for the info... My *next* question was going to be concerning
the appropriate gauge sheet metal to use... I was at a commercial
construction site today and they were doing the interior walls with
the sheet metal 2x6s... They were cutting off pieces from 4-6 ft in
length and throwing them in the dumpster... Seemed about the right
thickness, so I picked up a couple of them... At the very least, it
will give me plenty of metal to practice on before I go burning holes
in the floor pan of my XJ...

> Good luck about 3 beers *** skill level..

That 3 beers per hour, right?

Re: XJ floorboard holes
 

On Sun, 3 Jun 2007 17:15:10 -0400, "TF" <flannery16@insightbb.com>
wrote:

> Get 20G steel from local sheet metal place

Thanks for the info... My *next* question was going to be concerning
the appropriate gauge sheet metal to use... I was at a commercial
construction site today and they were doing the interior walls with
the sheet metal 2x6s... They were cutting off pieces from 4-6 ft in
length and throwing them in the dumpster... Seemed about the right
thickness, so I picked up a couple of them... At the very least, it
will give me plenty of metal to practice on before I go burning holes
in the floor pan of my XJ...

> Good luck about 3 beers *** skill level..

That 3 beers per hour, right?

Re: XJ floorboard holes
 

On Sun, 3 Jun 2007 17:15:10 -0400, "TF" <flannery16@insightbb.com>
wrote:

> Get 20G steel from local sheet metal place

Thanks for the info... My *next* question was going to be concerning
the appropriate gauge sheet metal to use... I was at a commercial
construction site today and they were doing the interior walls with
the sheet metal 2x6s... They were cutting off pieces from 4-6 ft in
length and throwing them in the dumpster... Seemed about the right
thickness, so I picked up a couple of them... At the very least, it
will give me plenty of metal to practice on before I go burning holes
in the floor pan of my XJ...

> Good luck about 3 beers *** skill level..

That 3 beers per hour, right?

Re: XJ floorboard holes
 

On Sun, 3 Jun 2007 17:15:10 -0400, "TF" <flannery16@insightbb.com>
wrote:

> Get 20G steel from local sheet metal place

Thanks for the info... My *next* question was going to be concerning
the appropriate gauge sheet metal to use... I was at a commercial
construction site today and they were doing the interior walls with
the sheet metal 2x6s... They were cutting off pieces from 4-6 ft in
length and throwing them in the dumpster... Seemed about the right
thickness, so I picked up a couple of them... At the very least, it
will give me plenty of metal to practice on before I go burning holes
in the floor pan of my XJ...

> Good luck about 3 beers *** skill level..

That 3 beers per hour, right?

Re: XJ floorboard holes
 

Grumman-581 wrote:
>... At the very least, it
> will give me plenty of metal to practice on before I go burning holes
> in the floor pan of my XJ...

I'd be picking up all the scrap they have to offer just for that reason
alone. Throwing a good weld is all in the practice. especially with gas
where you can blow through thin metal. Thankfully MIGs are more forgiving. :)

Of course now you will need a good plasma cutter. ;)

--
DougW

Re: XJ floorboard holes
 

Grumman-581 wrote:
>... At the very least, it
> will give me plenty of metal to practice on before I go burning holes
> in the floor pan of my XJ...

I'd be picking up all the scrap they have to offer just for that reason
alone. Throwing a good weld is all in the practice. especially with gas
where you can blow through thin metal. Thankfully MIGs are more forgiving. :)

Of course now you will need a good plasma cutter. ;)

--
DougW

Re: XJ floorboard holes
 

Grumman-581 wrote:
>... At the very least, it
> will give me plenty of metal to practice on before I go burning holes
> in the floor pan of my XJ...

I'd be picking up all the scrap they have to offer just for that reason
alone. Throwing a good weld is all in the practice. especially with gas
where you can blow through thin metal. Thankfully MIGs are more forgiving. :)

Of course now you will need a good plasma cutter. ;)

--
DougW

Re: XJ floorboard holes
 

Grumman-581 wrote:
>... At the very least, it
> will give me plenty of metal to practice on before I go burning holes
> in the floor pan of my XJ...

I'd be picking up all the scrap they have to offer just for that reason
alone. Throwing a good weld is all in the practice. especially with gas
where you can blow through thin metal. Thankfully MIGs are more forgiving. :)

Of course now you will need a good plasma cutter. ;)

--
DougW

Re: XJ floorboard holes
 

damn...forgot about the plasma cutter..than again I wanted tig too but
settled for gas option with the mig...
live and learn next project!
"DougW" <post.replies@invalid.address> wrote in message
news:5FS8i.165739$mJ1.57615@newsfe22.lga...
> Grumman-581 wrote:
>>... At the very least, it
>> will give me plenty of metal to practice on before I go burning holes
>> in the floor pan of my XJ...
>
> I'd be picking up all the scrap they have to offer just for that reason
> alone. Throwing a good weld is all in the practice. especially with gas
> where you can blow through thin metal. Thankfully MIGs are more
> forgiving. :)
>
> Of course now you will need a good plasma cutter. ;)
>
> --
> DougW
>