Great deals on TJ parts on Amazon!

Looking for parts for your Jeep Wrangler TJ? Checkout the selection of TJ parts Amazon has to offer, many with 2-day Prime shipping!

Click the image below to browse TJ parts on Amazon.

Jeep Wrangler TJ Parts on Amazon

We are a participant in the Amazon Services LLC Associates Program, an affiliate advertising program designed to provide a means for us to earn fees by linking to Amazon.com and affiliated sites.

Getting started on my floor pans and torque boxes

Andy-WhiteTJ

TJ Enthusiast
Joined
Nov 5, 2020
Messages
460
Location
Poughkeepsie, NY
I saw the photo of the seam sealer you're using. You may want to use something that can be used in a caulking gun. It would be easier to apply. Something like this:

7100402_dtn_550_pri_larg.jpg
 
  • Like
Reactions: Vtx531
OP
Vtx531

Vtx531

TJ Addict
Joined
Nov 17, 2020
Messages
1,348
Location
Kalamazoo, MI
One coat of bondo is on. Not really sure when to call the first coat good. The middle of the rocker is pretty flat. The ends are not flat but the panel started out wavy to begin with (probably due to earlier days when I bolted angle iron rocker guards on). I feathered the edges but not going to worry about making the ends totally flat. Fender flares cover up some of it.

I need to do another coat to fill in some pits and gouges.

Easy to see why a lot of people put rocker covers on top but I like the look without them and I thought I should at least make an attempt. I can always cover them up later if I need to.

98902406-773C-4687-9911-85AB443B67A0.jpeg
 
OP
Vtx531

Vtx531

TJ Addict
Joined
Nov 17, 2020
Messages
1,348
Location
Kalamazoo, MI
Finished for now. Ready for fender, seat, console, roll bar. Going to leave the carpet out until whenever I get around to doing the passenger side.

I need to get some new oval floor plugs.

65F8B8AE-EC2D-41DF-97F1-31992239E775.jpeg
 
OP
Vtx531

Vtx531

TJ Addict
Joined
Nov 17, 2020
Messages
1,348
Location
Kalamazoo, MI
I was able to take it for a drive today for the first time since this all started. I’m not completely done (obviously) but it felt great to drive the Jeep again.

I’d like to do the passenger side over this winter and exterior paint next spring or summer when the weather warms up again. Never ending project!

4B369293-1466-4AA4-81B0-1E72EAFD8609.jpeg
 
  • Like
Reactions: CV04TJR

eastbloc

TJ Addict
Joined
Oct 9, 2018
Messages
1,121
Location
FL
I was the same way the last year. Looking at you photo, I wonder if it wasn’t acut ally a case of hiding the rust with Bondo? Jeep puts a ton of seam sealer on that spot from the factory all around the roll bar base and that entire corner. It looks and sands/grinds off similar to bondo…not sure if that would make you feel any better if maybe the previous owner didn’t try to deceive you. You can see some of the remnants of seam sealer on my roll bar attachment plate in the above photos.

Now to go slap some Bondo on my rockers…

You are correctomondo!
I have been getting rid of bedliner from inside, and slowly digging into the area around roll bar, for what ever reason there is way more seam sealer on left side than right. I cut roughly an inch worth of it from the edges before i got to clean metal, rest was rusted under it.

Looks like you are slowly but surely getting somewhere with yours. I know the feeling of feeling great driving the Jeep, i dont get to see my for 3 to 5 month out of the year, and when i do get finally behind it, smile to the ears

PXL_20211011_214443882.jpg

PXL_20211011_214418378.jpg
 

ExitLeft

Gray would be the color, if I had a heart
Supporting Member
Joined
Mar 7, 2021
Messages
64
Location
Philly ‘burbs
Love this thread! Read with total anticipation and was heartbroken when you were considering throwing in the towel. Glad to see you didn’t, I wish I had 1/4 of your ability. Never touched a welder in my life.
I absolutely love threads like this. Keep it up and let me continue to live vicariously through you in this thread.
 
  • Like
Reactions: Vtx531
OP
Vtx531

Vtx531

TJ Addict
Joined
Nov 17, 2020
Messages
1,348
Location
Kalamazoo, MI
Love this thread! Read with total anticipation and was heartbroken when you were considering throwing in the towel. Glad to see you didn’t, I wish I had 1/4 of your ability. Never touched a welder in my life.
I absolutely love threads like this. Keep it up and let me continue to live vicariously through you in this thread.
Thanks, means a lot! You made my night.

I got into the nitty gritty part of the job again. Man, I forgot how not fun this part is. Rust everywhere and it really feels like I am causing destruction and making things worse but I know it can be done!

AA66F786-9F7C-4020-AF62-1F6C968EFBE0.jpeg


34A86991-01BE-4DF0-B80A-1F5B18CC8EB9.jpeg


ABDEB5DA-841D-48F7-BD14-B7C54FF4505E.jpeg


BA20DB71-5640-4F69-BD1B-DE89474DC6E5.jpeg


FFAF46AA-F147-4C7E-AA8D-59DF6E1F689D.jpeg
 
  • Like
Reactions: ExitLeft
OP
Vtx531

Vtx531

TJ Addict
Joined
Nov 17, 2020
Messages
1,348
Location
Kalamazoo, MI
I haven't updated in a while- Lack of motivation lately. Every time I go out in the garage to work on this, I stop after 5 minutes and don't feel like continuing. So pretty much no progress.
 
  • Sad
Reactions: ExitLeft

CV04TJR

TJ Enthusiast
Supporting Member
Joined
Feb 26, 2021
Messages
122
Location
Ponder TX
You did a good job on the first side. Rust repair is tedious and not the most fun but you can get it done.
 
  • Like
Reactions: Vtx531
OP
Vtx531

Vtx531

TJ Addict
Joined
Nov 17, 2020
Messages
1,348
Location
Kalamazoo, MI
I made friends with my cutoff wheel again! Some good progress today. I tried a new technique at the front lip and side rocker panel using cutoff wheels to grind the spot welds and it seemed to work nicely.

8CAC6950-6D9F-4DC6-82D5-17CA5DEAAAC2.jpeg


FA791286-E9A3-4E40-B1F5-E2A552F64671.jpeg


8D72FD04-42ED-4A68-9E61-FD936F5338A8.jpeg


07D171FC-830C-4583-B5B3-4FFB0201040B.jpeg


218005A6-EA3B-4FBC-AF51-8246D4AA2E7D.jpeg
 
Last edited:
OP
Vtx531

Vtx531

TJ Addict
Joined
Nov 17, 2020
Messages
1,348
Location
Kalamazoo, MI
Worked on it a couple hours today

Here is my overlap instead of buttjoint. Precision measured it by the width of a prybar haha.

21B27992-A88E-4C24-807D-FA6E639E069B.jpeg


Pan mostly fits. I had to cut the flange off the top left of the pan and will lap joint it to the existing good flange. Had to cut sort of a relief pie cut in my tub at the bottom right corner.
13631F32-D733-468F-8B51-1DBE7D158396.jpeg


Started on the rear. Best technique is to just start cutting! It gets easier as you go and more gets cut out. BE CAREFUL NOT TO CUT THROUGH THE SUPPORT STRUCTURE near the trans tunnel and seat mounting hole. Notice the shape I did my initial cut to avoid that area.
7CD31B35-AE68-4916-BF4A-AB0C9DD641B9.jpeg

Panel removed and ready to go further.
E2239DA8-EA33-468C-9DEF-5F0381A8EE0D.jpeg

Lots of rust inside the torque box!
9D1D5355-4DE4-4898-9801-D283EC7B85C0.jpeg

This photo shows the support structure spot welds cut out and I started carefully cutting off the floor pan without cutting into the structure.
A8A2111B-58F4-438D-B022-473F2E3C59CD.jpeg


To be continued...
 
Last edited:
OP
Vtx531

Vtx531

TJ Addict
Joined
Nov 17, 2020
Messages
1,348
Location
Kalamazoo, MI
You did a good job on the first side. Rust repair is tedious and not the most fun but you can get it done.
I meant to reply specifically to this earlier but thank you! You are absolutely right - tedious and not fun. Worst of all, the results will never be as you imagine in your head. I greatly appreciate the encouragement and it means a lot.

On a funny side note, my wife's BMW convertible is outside in a snow storm right now and has been since I started the Jeep rust repair project. So she is a good supporter too.
 
  • Like
Reactions: Squatch and CV04TJR

CV04TJR

TJ Enthusiast
Supporting Member
Joined
Feb 26, 2021
Messages
122
Location
Ponder TX
N
I meant to reply specifically to this earlier but thank you! You are absolutely right - tedious and not fun. Worst of all, the results will never be as you imagine in your head. I greatly appreciate the encouragement and it means a lot.

On a funny side note, my wife's BMW convertible is outside in a snow storm right now and has been since I started the Jeep rust repair project. So she is a good supporter too.
No problem we all get a little burned out sometimes. My wife is a good supporter too but I think if I had been making her park outside since September she would be getting a little annoyed with me by now.
 
  • Like
Reactions: Squatch
OP
Vtx531

Vtx531

TJ Addict
Joined
Nov 17, 2020
Messages
1,348
Location
Kalamazoo, MI
Couple more hours spent-
I got the remainder of the torque box removed. Got more of the back floor pan removed. Cut off the remaining old body mounts.

D83AF746-F556-41D9-B651-9E76557D13D2.jpeg


Mess of rusty metal removed at the rear. My old repair is holding up pretty well at the rear corner. It was totally rusted out after removing rocker guards a long time ago so I flux core welded in a patch. Bad job shaping the piece but it is covered by the flare and held up nicely.
1393EFCC-22E3-4DE1-B457-74EE709CF1E0.jpeg

I wanted to try and save this panel between the floor pans but it looks pretty bad and is time consuming to cut off the torque box flanges while trying to save the metal underneath.
A87D624E-AD02-4104-B522-CCB03AD12DF4.jpeg

Probably will be easier to just cut it out and I have enough of a panel leftover from the driver side that I had fabbed up for that spot.
9DE4D6EC-69D8-419A-A5AC-74F67F968D17.jpeg


Also, I was using a crowbar to pry apart panels and it slipped. Lucky I had safety glasses on! The sharp chisel edge bounced off the safety glasses and cut my cheek bone area. I normally don't wear safety glasses when using hand tools but it might have saved my eye today. So lucky I had them on due to using the cutting wheel previously!
 
Last edited:
  • Like
Reactions: CV04TJR
OP
Vtx531

Vtx531

TJ Addict
Joined
Nov 17, 2020
Messages
1,348
Location
Kalamazoo, MI
Now we are getting somewhere!

I cleaned up (cut out rusted metal) in the rear wheel well area. Must have been some spot welds there but it was a mess of rust and I couldn't discern what was what so I just cut it off. I didn't have that problem on the driver side because it was completely gone from being rusted out so much worse.

I drilled out the spot welds along the rear flange. My spot weld cutters were not working very good for some reason so I resorted to using a step drill bit. (still need a damn rotobroach mikeH) I had intended to go up from the bottom so as not to have visible holes in the flange but I ended up going from the top to make it much easier and save a lot of time.

I removed what was left of the floor pan at that rear flange and cut out a closer outline of where the final cut will be all around - enough to get the new pan loosely into place. I had to notch the new floor pan at the back inside corner to get it to fit with the existing pieces back there (same as I had to do on the driver side).

Time spent today: 2h15m

F27C1FFF-342E-402B-919A-20070EE57828.jpeg


BDA87A78-2972-4FFF-BEA3-6B15E5ED187E.jpeg


22C4C07E-3A85-4227-80B6-0C87FD40C252.jpeg
 
Last edited:
  • Like
Reactions: CV04TJR
OP
Vtx531

Vtx531

TJ Addict
Joined
Nov 17, 2020
Messages
1,348
Location
Kalamazoo, MI
Three more hours today. I decided to keep the original center part between the pans so I spent some time cutting and grinding off the remainder of the torque box that was attached to it. Ground down and smoothed out all the spotweld cutoffs that were protruding there and elsewhere. "cleaned up" a bunch of other areas. Hammer/dollied some flanges to get them back to flat. Did some pie-cuts at the corners of the flange on the tub at the rear floor pan.

Did a test fit with fasteners and the torque box fitup.

Getting there...

E6DA6D24-C8EC-47E0-95B1-606146DC8322.jpeg


B1CA86DB-96E6-41AC-A2BE-71F0CE2F256C.jpeg
 
  • Like
Reactions: CV04TJR

Yoda

TJ Enthusiast
Joined
May 5, 2021
Messages
202
Location
MA
Nice work! This is going to be my life shortly as I'll be doing the same thing!
 
OP
Vtx531

Vtx531

TJ Addict
Joined
Nov 17, 2020
Messages
1,348
Location
Kalamazoo, MI
Looking good buddy hang in there !
Nice work! This is going to be my life shortly as I'll be doing the same thing!
Appreciate it guys! Yoda - hope this thread helps. There are many ways to skin this cat so I look forward to seeing how you do it.

I ground down more of the protruding spotweld cutouts. Think I got them all done. Used an air needle scaler everywhere I could that needed it on the frame, body mounts, support piece under rear pan, roll bar mount, front oem spot welds on the firewall (works great to "fix" the ones where rust is bubbling on top).

Who says you can't use a needle scaler on the body sheet metal. It worked pretty damn good to find the bad spots.

EA37B117-B271-49AE-BE46-A818F2799808.jpeg


Used grinder with wire wheel to remove all my former bondo repairs. Not sure what to do about the rust. Obviously where there are holes it needs to be patched. Maybe I can get by with sand blasting the areas that aren't rusted through. Sortof what I did on the driver side because there was no rust through.
3237C440-FDDC-447D-B065-DC8238B33DA9.jpeg


My old patch on the left was holding up pretty well and other areas where I had filled 1/2" bolt holes from rocker guards a long time ago also held up well, no rust. Can't hardly see the bolt hole repairs in this pic.
13EE1667-54FA-46C9-9720-20187286F339.jpeg



Next step is get metal, make patch panels, cut out old, weld in new. Garage is a white powdery dusty mess now again from grinding the body filler.