Driver footwell and rear cargo floor rust from the inside-out due to water leaks. Cut, patch, weld, seam-seal.
Floor pan rust on XJ is endemic in the salt belt and surprisingly common everywhere from rear-hatch and windshield leaks. The driver footwell rots from condensation and snow on boots; the rear cargo floor rots under the spare tire and from the rear hatch wiper leak (see separate entry). Repair process: pull carpet (six trim screws + sound deadener), assess extent of rust with a screwdriver poke test - any flaking that comes off is gone. Use a Sawzall or angle grinder to cut out the bad metal back to clean, then cut a patch from 18-gauge sheet steel matching the original contour. Weld in with MIG, grind flush, prime, paint, and apply seam sealer (3M 8531) to all joints. Spray cavity wax inside the rocker panels and frame rails (FluidFilm or NH Oils) annually to slow future rust. Driver footwell pre-formed patch panels are available from Aussiehavoc.com, BodyPanel.com, and Tablerock or you can fab from sheet.
| Part | Vendor | Est. price |
|---|---|---|
| 18 ga sheet steel (2x2 ft) | metal supply | ~$30 |
| Seam sealer | 3M | ~$20 |
| Floor pan patch panel (driver) | Aussiehavoc | ~$80 |
Written and maintained by an AZ wheeler and driveway wrencher. Always cross-reference your factory service manual — modifications affect vehicle safety and warranty. Work at your own risk.