1. Preparation:
* Safety First: Wear appropriate safety gear: gloves, eye protection, respirator (for welding fumes and grinding dust), and hearing protection. Work in a well-ventilated area.
* Assessment: Thoroughly inspect the extent of the rust. Determine if you need to replace just sections or entire panels. Take lots of pictures and measurements.
* Parts Acquisition: Source replacement floor pans and rocker panels. These are often available from salvage yards, aftermarket suppliers, or specialized Jeep parts retailers. Ensure they're compatible with your Cherokee's year and model.
* Tools and Equipment: You'll need a welder (MIG welder is recommended), grinder with various cutting and grinding wheels, wire brush, metal shears, hammer, dolly, body filler (if needed for minor imperfections), seam sealer, primer, and paint. Jack stands, a jack, and other basic automotive tools are essential.
2. Removal:
* Vehicle Preparation: Safely raise and support the Jeep on jack stands. Disconnect the battery.
* Interior Removal: Remove the affected interior components (seats, carpet, etc.) to access the rusted areas.
* Rust Removal: Use a grinder with a wire wheel or cutting disc to remove all loose rust and compromised metal. Be careful not to cut into good metal more than necessary.
* Panel Removal: Carefully cut away the rusted floor pan and rocker panels. This requires precision to avoid damaging surrounding areas. Try to leave as much of the surrounding structure intact as possible to provide a good welding surface.
3. Installation:
* Fitting the New Panels: Position the new floor pan and rocker panels, ensuring proper alignment. Often, some minor adjustment or fitting might be required. Use clamps to hold them in place.
* Welding: Weld the new panels securely to the existing structure. Use proper welding techniques to ensure strong, even welds. Multiple, short welds are better than long continuous ones. Avoid burning through the metal.
* Grinding and Smoothing: After welding, grind down the welds to create a smooth surface.
* Seam Sealer: Apply seam sealer to all welded joints to prevent future rust.
4. Finishing:
* Body Filler (if needed): Use body filler to address any minor imperfections or gaps.
* Primer: Apply a coat of primer to prepare the surface for paint.
* Paint: Paint the repaired areas to match the existing vehicle color.
* Reassembly: Reinstall the interior components.
Important Considerations:
* Undercoating: After the repair, apply a rust-proofing undercoating to protect the newly repaired areas and the rest of the undercarriage.
* Professional Help: If you encounter any unexpected challenges or are uncomfortable with any aspect of the process, seek professional assistance. This job is complex, and improper repair can compromise the structural integrity of your vehicle.
* Photography: Take detailed pictures throughout the process. This will be invaluable if you encounter difficulties or need to revisit steps.
This is a simplified overview. Specific steps and techniques may vary depending on the extent of the rust damage and the year and model of your Jeep Cherokee. Consult a repair manual specific to your vehicle for detailed instructions and diagrams. Remember, safety should always be your top priority.
