Rust! Lots and lots of rust and holes in the floorboard.. I would have never purchased this car if I knew the rust was going to be this bad.. But now that I'm here, I might as well go ahead and fix it.

I plan on welding in some new sheet metal, installing new padding and carpet, then fiberglass for the undercarriage.

Does anyone have any recommendations?

Also, I need help with a few things if you don't mind?

1) Need to know how to get the center console out (to install new carpet)

2) How do I remove the metal panels on the door seal?

Thanks guys! Always appreciated!

 

Might want to consider getting a donor car. Once the engine or Transmission fails these cars go for under $1,000. You would end up with a rust free car and a lot of spare parts.
When the engine died on my XJ8, the most I was offered was $300 for the car.

 

The metal panels are held on with super strong double backed tape. Might try heating with a heat gun or even a hair dryer. Some have used dental floss to 'cut' the panel free. I used a razor knife with the blade extended about 3 inches to ease it off. Worked without damage.

 

Lavaman
Here are the instructions & illustrations on removing the floor console in JTIS manual:

Floor Console PDF file
https://www.dropbox.com/s/1wfg041q31...le%20R%26I.pdf

Floor Console Extension PDF file
https://www.dropbox.com/s/ner6jjyzfv...on%20R%26R.pdf

Floor Console Finish Panel Bracket
https://www.dropbox.com/s/9s8n9y4n45...2076.25.26.pdf

Floor Console Ashtray
https://www.dropbox.com/s/7qrg6urfdt...2076.25.25.pdf

Floor Console Stowage Compartment
https://www.dropbox.com/s/9gqsed107s...2076.25.16.pdf

Floor Console Finish Panel
https://www.dropbox.com/s/b0gsja74j3...el%20R%26I.pdf

Here is the front door weather seal information:

https://www.dropbox.com/s/besyrti8xu...ip%20R%26I.pdf

Jim Lombardi

 

WOW that's some major rot!

how many miles on the car? what part of the country has it spent most of its life?

 

Yeah! It was pretty bad.. About 85% of the rust is now gone, and new sheet metal was welded in.

90,000 miles and it was spent in KY most of its life. Wrecked, totaled, and literally just sat for years.

 

how much time and money did you spend with this?

 

props for bringing her back to life! It looks like pacific blue for exterior colour, if that's so you've got a rare and excellent colour!

 

Sheet metal - $50 or so
Spot weld by me - Free
Quicksteel - $150

I began by cutting out the old rust with a saw, then measuring, sawing and bending new sheet metal to fit perfectly over the holes. After that I spot-welded the sheet metal, applied quicksteel to seal it thoroughly, then sprayed the undercarriage with rustoleum, and finally applied bondo/fiberglass to seal the undercarriage.

 

Thanks! Actually it's just a metallic black

It will actually be re-painted next month, so maybe I'll try the pacific blue!

This has been a long and painful journey trying to get her mechanically and aesthetically sound, but I'm almost officially done! Then comes mods

 

So here are a few pictures of the interior so far.

What's new or changed:

-New sheet metal on floorboard.
-New padding.
-New carpet (plush, house carpet)
-Marine vinyl headliner, trim and handles.
-Center console wrapped in two-tone black leather/camel marine vinyl.
-Hand-stitched sun visors camel/black piping. (Getting better at sewing.. lol)

I still have a few additional mod ideas for the interior.. But this is what I've completed so far.

The marine vinyl is some great stuff! And I love driving with no shoes

 

Thanks for sharing the great story with pictures. Nice to know you didn't give up. They are great cars once you get them working right. May you get many miles/years enjoyment from it.