So I need to replace the flooring around the driver side where the seat belt attaches to the floor. The area has almost rotted away and no way it will pass inspection without this fixed. Any ideas on where to start. I know I will have to cut out the rotted area and replace the floor panel. But how, and what tools are required?
A cutoff/grinder with a thin cutting disk should be the main tool. Cut a nice even square around 2-3 inches around the size of the hole. Then get some steel plate from a steel yard. I'd use 1/4 inch if you can get it. Line it up, weld, grind down the uneven edges, paint and enjoy.
Shouldn't take you more than an hour if you have access to a welder.
Denis A. Baldwin
1991 YJ 99 Vortec 5.7L, SM465, NP205, 14 Bolt Rear, Dana 60 Front, 5.13 Gears, Detroit Lockers, 395/85R20 46" Michelin XML tires on 20" XD Wheels, Cherokee Offset Springs (10" front to back stretch total), Bilstein 5150s, 1in. BL, custom cage, Warn M8000, Double D Dash/OHC, 4Low Front Stinger Bumper, DirtWorx Rear Bumper WTC, Tube Fenders, Comp Cut, 1 Ton HD Kingpin High Steering and PAID FOR.
I don't know about that denis. I went through all of this on mine last summer and it will most likely get more involved than that. First off, you will need to remove the roll cage in order to preperly get to the rusty area. I had to drill out most of the bolts holding the cage in. Aside from that, the floor pan is spot welded to the support brace underneath. Be careful when cutting through the floor not too cut too deep and cut into the brace. The spot welds can not be seen until you start bending the floor up. Once you find them you can drill, chisel, or grind them out.
You can either buy a replacement floor pan from Quadratech or build your own patch. I think floor material is 16 guage steel. There is a small hump in that area for clearance for the body mount bolt. I used a ball pean hammer to make that and it didn't turn out too bad. The preferred methoud id to weld in the patch, but you can use adhesives too. I havent tried this, but it can be done. I will have to check if I have any pics of this to help, but I don't think I have any.
Daddyjeep is right on the money. i have a 91 yj that i have been working on since november, not hat its particularly hard work just time consuming and i have a full time job and im a full time student. both of the front floor pans were completely rotted out so i bought the quadratec replacements trimmed them down a bit and welded them in. behind that was the worst part. right where the seat belt mounts was almost completely gone all the way to the inside part of the roll cage brace. I took the roll bar out having to drill out half the bolts then cut all the rust out with a cut off wheel. i bought 18 gauge steel to replace these sections which i believe is plenty strong. i also reinforced the body braces with angle iron where the roll bar sits. i made cardboard templates of the missing floor sections, and from then on it was just a lot of cutting, bending, and welding.