Body Work Repair

Dashside Strengthener

mrt 122009

Beside the shutface pilar, this area is often rusted badly. However my car was not rusted these places also need extra attention. Not very strange these places rust away because all water and dirt are kept together inside lower part of the dash side strengthener. Maybe we have to drill one or more big holes in the bottom to prevent that water and dirt will stay there.

First I removed all material below the 70% (original material left) and then remade all missing parts. Sprayed again everything in zinc paint and welded everything back to there original positions.

Left Side Right Side

Gearbox Cover I

Gearbox Cover No Responses »

aug 032009

Before I could start with fitting the gearbox cover the bulkhead and driveshaft tunnel needs to be fixed.
For some reason it looked like they have removed the gearbox from the car compartment, and needed some extra room. They used a chisel to open up the bulkhead and drive shaft tunnel for about 4 inch.

I had to reproduce or buy a gearbox cover because this part was not available anymore. Buying one on the internet is very expensive (used or new) so I decided to make one myself from the sheet metal left from the other jobs.

In the direct neighborhood of my home there is a jaguar garage situated and I could borough one from them. It was a cover from a XK150 but they should be interchangeable and could be used as an example.

Left Front Wing

Front Wings, Left Front Wing No Responses »

apr 172017

One of the last big metal work pieces are the front wings. After the left front wing was cleaned thoroughly the following repairs need to be done before the wing can be painted inside.

The valance assembly has several holes of 1″” drilled for some unknown reason.
Headlight pod has extensive rust in the under side of the headlight mounting area.
The lower edge of the front side has a small hole due to rust (about 2″ by 1/4″)
The steady bracket which mount to the battery box has some rust
Dents in the area around the flashing light (due to badly repair after a collision in the past)

Cleaning the inside

The inside of the wings are protected with a very tick layer of tar which protected the inside from rust.
From the photo it is clearly visible that it did his you very well. The right side, the part behind the mud shield, which was not protected is much more affected by rust.

After the layer of tar was removed with a small torch and a putty knife the undamaged metal became visible.

When the whole surface was cleaned with a poly-carbide steel brush the front wing looks like new again. All difficult to reach area’s are now sandblasted so the inside is now ready to receive the first layer of epoxy primer.

Headlight pod

Due to long lasting condensation inside the headlight pod the lower part has been damaged by extensive rust. First the lead, used to smooth up the connection between headlight pod and front wing, is removed. Now all by rust affected material is removed and the holes in the front wing are welded. Now we know how much material is missing we can start with producing the new pieces.

The new pieces are fitted for the last time and welded unto the headlight pod. The last step is reapply the lead to smooth out connection between the wing and headlight pod.

When I was investigating the headlight pod from the right side front wing (which is not rusted at all) i found a small hole in the lowest part. My first impression was that there was a small hole due to rust but after looking in more detail to the inside area it looks like a small hole to drain water. I will make such a hole in the left headlight pod as well.

The valance assembly

The holes in the left front valance, which are certainly not original, needs to be removed. In total 9 holes where drilled. With this amount of holes it is better to just remove the hole affected area as one piece and remove it for a new piece.

Painting

The inside inclusive the valance will be painted in the following order:

Epoxy primer
Body schutz (Protective coating helps protect from corrosion and chips)
The inside will be painted satin gloss
The following parts are painted in Pearl grey
- Valance assembly (both sides)
- Headlamp light unit container (inside)
- Side lamps casing (inside)

Left Rear Wing

Left Rear Wing, Rear Wings No Responses »

jul 312017

Repair

The left rear wing has two attention areas;

The lower edge at the door side
The upper part also at the door side

The repair areas marked with grey paint

Cleaning

Now that the rear wing has been repaired the thin layer of rust can be easily removed with a wire brush and sand paper.

Painting

Now that the inside is nicely shining again the following activities can take place;

Apply a fresh layer of Epoxy primer.
Make sure all seals are seamed. (3M Heavy Drip-Chek Sealer)
Apply a protective layer to prevent chipping. (3M Textured Anti-chip Coating)
Last but not least a layer of satin black paint to make it easier to clean the inside.

Lower Rear Panel

Lower Rear Panel No Responses »

aug 012010

When I received the car I already noticed the damage on the lower rear panel. I looked like some kind of parking damage maybe 40 years ago. The metal hidden behind several layer of paint and tick layers ot putty was completely crumpled and beyond repair.
This is a very difficult part to make by your one because it is curved in two directions. This is only possible with a the help of a English wheel, which is not available in a do it your self workshop.
After a small search on the internet I found a guy in Madeira who could deliver this part for only €165 (including shipping costs)
The URL of this company is http://www.nsfcoachbuilders.com/sale_parts/Jaguar_XK_140

After the new panel was remounted the overlapping areas on both sides should be filled with lead. I don’t want to use putty because originally they used lead as well. Lead soldering looks easy but it is much more difficult as it looks. The advantage is that the lead can be reused time after time. So with a lot of patient I succeeded at the end. With just a thin layer of zinc spray everything looks like new again.

Right Front Wing

Front Wings, Right Front Wing No Responses »

apr 222017

One of the last big metal work pieces are the front wings. After the right front wing was cleaned thoroughly the following repairs need to be done before the wing can be painted inside. The right front wing is in a much better state the the left one so this repair is rater easy.

Dents in the area around the flashing light (due to badly repair after a collision in the past)
The lower edge of the wing nearby the right door has a lot of rust. This together with the lower part of the door hinge plate needs to be repaired with new pieces of metal.

Cleaning the inside

After I followed the same procedure as with the left front wing this wing also looks like new again.

The lower wing edge

The state of the lower front wing edge partly rusted away and replacing this whole area is inevitably.

Cut out of the rusted part

Painting

Now that the right front wing has been cleaned and repaired it can be painted. We start with Epoxy primer followed by a protective layer to prevent chipping and as last a layer of black paint. This last layer of paint will make it easier to clean the inside. The parts visible from the engine compartment will be painted in the car color.

Right Rear Wing

Rear Wings, Right Rear Wing No Responses »

jul 312017

Repair

The right rear wing has three attention areas;

The lower edge at the door side
The upper part also at the door side
the lower edge on the backside of the car

The repair areas marked with grey paint

Cleaning

Now that the rear wing has been repaired the thin layer of rust can be easily removed with a wire brush and some sand paper.

Painting

Now that the inside is nicely shining again the following activities can take place;

Apply a fresh layer of Epoxy primer.
Make sure all seals are seamed. (3M Heavy Drip-Chek Sealer)
Apply a protective layer to prevent chipping. (3M Textured Anti-chip Coating)
Last but not least a layer of satin black paint to make it easier to clean the inside.

Shutface Pillar

Shutface Pillar No Responses »

jul 072009

My first sheet metal job was the shutface pillar. This area, which is normal for these type of cars was not very good anymore. I started with removing all damaged material and removing all old paint and dirt remaining’s. All sub parts for the Shutface Pillar, at least 10 for each side, are spot welded together before welded to the car. All areas where the light never shines are painted with zinc spray to prevent rusting.

Shutface Pilar Left

Inside Shutface Pilar Right

Outside Shutface Pilar RightAs seen on the above photos my first sheet metal job was very successful.

Remark:
Always keep the body bolted on to the chassis during welding jobs to prevent the body will warp or twist

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