I bought a 1998 Tj Sport last week and the guy who sold it to me included a Herculiner kit. He had the carpet ripped out but never got around to putting in the liner. Since I had a three day weekend, I decided to go ahead and knock it out. Spent Saturday tearing everything out (roll bar was a PITA!) and prepping the tub. I taped everything this morning and busted out the Herculiner. It's been kind of cold here, so I kept the Herculiner in the house overnight to keep it at a more usable temp. I opened the can and tried mixing it up.
If you've never used Herculiner, all the rubber particles settle in the bottom of the can and you have to mix it well before use. Well, THIS can was damn near solid rubber on the bottom. I had never used Herculiner before but a buddy did his truck bed and I remember him saying it was tough to mix, so I thought it was normal. After about 30 minutes of hacking at the rubber bottom, I went and bought a paint mixer from Lowes. Another 10 minutes with the mixer and I had it mixed as good as it was gonna get, but there were some big chunks of rubber in there (1/4-1/2"). I was able to use about 2/3 of the can on the tub but was constantly having to pick out chunks of rubber.
To finish up the job, I bought an extra quart from the parts store. What a world of difference! This stuff mixed completely in about 2 minutes using the paint mixer. No chunks at all. I finished the second coat and it's drying as we speak. All in all, I'd say it turned out pretty well. I've got a few bigger chunks of rubber in the finish, but not too bad. No pics yet.
SOOOOO, the moral of the story. If you're using Herculiner....make sure it is not old product. Who knows how long this guy had it in his garage, but I'm guessing that it was a long time. And if you do open a can you just bought from the store and the bottom feels like a solid chunk of rubber, take it back and get a new can.