So recently I got a 93 2 door 5spd for a few hundred bucks. It seemed like a great deal until I looked under the jeep..I swear I didn't even know it was possible to get that much rust under an xj. But I was just wondering if I should fit new metal to the jeep and weld it in, or just put a large piece over it all and weld it together after cutting out all the rust. Body work is definitely not my strong point here and I'm not looking to impress anyone here with my bad welding/fabrication skills hah. Thanks for any help though, and if it gets extreme enough I might make a build thread

 

Cut out the old and replace with new, that's the best way

 

It's a marvel.

What's rusted out, the floors? Replacement floor pans and rockers are available from a couple of sources, or you can bend up your own. If it's the frame rails that are rotted out, I'd think twice about spending another dime.

 

Check out my build thread in my sig. Been 4 years since i tackledy rust and i am still wheelin strong. Have any questions i will do my best to help you. Didnt weld none of it.

Granted i would have if i had a welder and the skill lol

 

Patch it up. I've got a solid four square feet (combined) of stainless sheet in my Jeep. It's all held together with rivets and silicone (to keep moisture out). It's been on there for well over 25,000 miles and many wheeling trips. It still looks as good as the day it was installed.

 

Ok so I double checked to see if the frame rails were rusted and they arent! I might take a few boxes of bedliner or something to the entire bottom of the jeep after Im done welding in some new floor panels.
I do like the Wagoneer build! Ive honestly never seen one around where I live, but then again it seems like the only kind of jeep people buy down here are wranglers..I might try to use the welder until it starts to look bad, then rivet it all together

 

Both sides of my floor were rotted out and I used big pieces of sheet metal from and old roof. Painted them up and pop rivetted them in and sealed it with tar worked great. The front of the rear leaf shackles was not so easy however had to take it to a guy who bent and welded plates in.

 

Floors rusting out is a really common problem.

I spent $100 on a Harbor Freight welder and fixed mine. It was fairly easy.

 

I think I have the exact same welder. What Im going to do is buy more metal than I need just in case I need it. Ill def have to paint it though so that doesnt rust away before I use it, but like I said Im going to weld a few pieces first and if I dont think its safe enough Ill go with the rivets