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Thread: 96' XJ - Summer Floor Project :)

  1. #21
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    I think you can only do 10 at a time, still not sure why they're not in order but you get the idea...

    Welded both front and rear driver side, cleaned up the welds and slag, seam sealed where I thought it was needed, ($11 a bottle) and then ended up coating the whole floor in the primer.

    Next is the passenger side
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    '95 YJ, 31" Goodyear Territories w/ Black Steelies, Rubi Flares, Lined tub
    ...some tough lookin' grab handles

    '96 XJ 4.0 Stock

  2. #22
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    Hey, are you going to patch underneath the tunnel on the driver side?... I can see the ground through it haha looks good so far though

  3. #23
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    Haha, ya I am, to me it looks like the stock floor went underneath that and went all the way through front to back, I didn't realize this until after, and I wanted to keep that tunnel there becase it was still in good shape. I think I'll weld a plate on from the underside now. At least I'll still be able to spray it with primer too from above it using the holes in the tunnel.

    I've also undercoated everything so far but haven't taken any pictures.

  4. #24
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    Well I surpised myself a bit today and got the majority of the front passenger panel in. I've been getting the hang of the welder a bit more and have improved on each panel...I'm not the best at it but it's comin' along for sure and it's solid.

    I actually found a street sign post that wasn't being used and I'm gonna use that as the seat mounting tunnel/channel, although I'm going to wait until I put the rear panel in before welding it in place. I figure I'll make a seam underneath the tunnel then weld the flaps of it to either side, onto the new panels. I think this should beef up the seam a ton and hide it too.

    Hopefully by the end of the week I'll put the rear in, although I have to replace the muffler too and I was planning on doing it from above since I have easy access to it...

    So far I'm pretty pleased, keep the comments/suggestions coming.

    **Any ideas on a cheap/decent muffler? Just looking for something to pass the e-test pretty much.
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  5. #25
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    Couple more shots...
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  6. #26
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    I purchased a thrush high performance welded muffler for around 55$ for my cherokee. Its a cheaper version of a flow master 40 and sounds sick. I highly recommend it. Its a sweet welded muffler for a decent price

  7. #27
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    Quote Originally Posted by dontshityourpants View Post
    I purchased a thrush high performance welded muffler for around 55$ for my cherokee. Its a cheaper version of a flow master 40 and sounds sick. I highly recommend it. Its a sweet welded muffler for a decent price
    Awesome, can I order it from PartSource or CT? Or do I need to go somewhere more specific? Also, when you say welded...can I still just use U-bolts to clamp it in place? never done a muffler before, thanks.

    *EDIT, found it on their website actually...I'll check it out this week. thanks again
    Last edited by JeepYJ44; 05-23-2011 at 09:45 PM.

  8. #28
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    Got some more work done this evening after work...mocked up the rear passenger panel, cut out the old muffler and that was about it...plans for tomorrow (weather permitting) to get the new muffler in, and weld in that panel...then I'll work my way to the rear.

    ...think it was time for a muffler?????

    Also, the other day...the old seat mount supports were rotted out so I took a piece of thicker steel I had lying around and patched one, and the other I cut a piece of a galvanized street sign post to an L shape and used that...seems super solid.
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  9. #29
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    Muffler shots and some others...
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  10. #30
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    Pretty much done most of the welding in the floors now...
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  11. #31
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    I forgot to mention I needed to do underneather the rear seat where the tub dive down...I guess water must pool there over time and just rot away those poor floors
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  12. #32
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    There's a few small little details I need to finish up but the welding is pretty much all finished...I need to go back and tir in the frame rails in a few spots...I was thinking of leaving the self-tappers in place cause I sort of like the look...but I wasn't sure if they're very strong...any input on that would be cool.

    I got a tank out of a '91, gave er a quick sand and hit it with some flat black...it wasn't dry when I took the picture obviously. I popped the pump and sending unit out of my tank too so I can swap them...the PO told me the pump had been replaced so now I actually got to see for myself and it had been for sure.

    Still need to pop the new tank in...gonna do the fuel filter while I'm there, also do the rockers on the passenger side, and bedline everything...then i'll see how long it take me to remember how it all goes back together

    It's coming though...and I think my welds are getting better
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  13. #33
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    any updates how are you making out with it
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    96 ZJ 4.0L 33x15 BFG'S

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