Rusty sills fix! Follow along please.............

[andyfanshawe]

Ok, here we go.  Got a
cheap 2000 S type 3 litre V6.

 

Plan is to restore and sell on in really good condition.  Possible the only S type with rust free
sills!

 

 

 

Did have a jag service history till about 2010,
then......who knows.

 

Ended up with a gentleman who left it standing for 2 years
because he wasn't allowed to drive anymore, and,.....................oh, this
is boring, so lets get on with the rusty sills.

 

 

 

Sill cover off on the drivers side (remove the black clips
from underneath, remove the mudflap by drilling out the rivet from underneath,
and  pulling it off the cover.  Go under front wheelarch and peel back the
lower corner and remove the torx screw that goes through the wing into the sill
cover.  Then just pull the cover out
horizontally to remove it from its clips.

 

 

 

Here's the first view from the front of the car towards the
back

 

 

 

 

 

 

 

 

Just in front of the back wheel

 

 

 

 

 

 

Underneath just in front of the rear wheel where the sill
flanges have collapsed when jacking up

 

 

 

 

 

 

 

 

Further forwards

 

 

 

 

 

 

More damage, tip of iceberg style

 

 

 

 

 

 

First cut and outer skin peeled down

 

 

 

 

 

 

Been full of water eh?

 

 

 

 

 

 

More revealed further back

 

 

 

 

 

 

And furthest back

 

 

 

 

 

 

 

 

 

 

Oops, last photo was wrong...

 

 

 

 

 

 

More at the back

 

 

 

http://cimg1.ibsrv.net/gimg/www.jaguarforums.com-vbulletin/1024x575/80-dscf0748_zpsgx9lhtmd_4ef235f2c0aa4622096a23db1e27c47dd2f981fd.jpg

 

 

 

Removing horizontal panel under floor just in front of rear
wheel

 

 

 

http://cimg7.ibsrv.net/gimg/www.jaguarforums.com-vbulletin/1024x575/80-dscf0749_zpsoseouijy_a9604a73cb9c399d46d1076d35d7da50734eba65.jpg

 

 

 

And removed

 

 

 

http://cimg0.ibsrv.net/gimg/www.jaguarforums.com-vbulletin/1024x575/80-dscf0750_zpsuwy91rhk_b8d68e7890c56d342472aa252e6b7aa499217c6a.jpg

 

 

 

Oh dear

 

 

 

http://cimg1.ibsrv.net/gimg/www.jaguarforums.com-vbulletin/1024x575/80-dscf0752_zps1h19pu0c_575bc33dcac5da646538ad11a3740fc26bfba6db.jpg

 

Better start putting some steel back at some point!

 

Andy.

[Claws]

Hi Andy

That looks really bad! Not a bodywork expert by any stretch of the imagination, but that looks like a massive and expensive restoration job? Made me scared to look at mine

[Old Peter]

Hi Andy,

 

Most cars do not like being left doing nothing.

 

You have a long job ahead and I would like to watch the journey.

 

Regards,

 

Peter.

[andyfanshawe]

Hi Steve and peter.

Not expensive for me cos I dont charge for my own labour!  But taking a gamble on this car.  certainly wasn't worth saving if I had to pay someone else to do it, but worth doing because its really nice in other respects.  Be good for someone when its done.  I've got 3 other customers resto's in, so this will have to go at some point.  But it will be awesome!!!

 

Part 2.......of the loooong journey.

Off with the right rear wheel and the inner arch liner.

Cleaned the steel up in the lower corner and only the first inch or two is weak

 

 

 

Cut out and a plate made and welded in

 

 

 

 

 

 

 

Media blaster out

 

 

 

 to clean up the top corner inside. 

 

 

 

 

Good penetration weld there!

 

Cleaned all sound metal but with surface rust and painted it with KURUST.  That aint coming back!

 

 

Next bit marked for cutting

 

 

This is the rear of the marked panel and the extent of the rust

 

 

Here is the area cut out and the panel behind media blasted and painted with kurust

 

http://cimg5.ibsrv.net/gimg/www.jaguarforums.com-vbulletin/1024x575/80-dscf0773_zpsydjz9cqw_decbdab9529039ded38e0ccaa86c4ff225b5099a.jpg

 

Ive left the lower lip in to make sure I know where the panels line up.

 

Cardboard templates made to mimic the original panels.  ie in 2 sections spot welded together

 

 

http://cimg9.ibsrv.net/gimg/www.jaguarforums.com-vbulletin/1024x575/80-dscf0776_zpsk8uhz6sr_1071fd0cebe1e6d89ce0cdcdc82bd5dbb8e09118.jpg

 

And cutout and spotwelded together with my trust spot welder

 

http://cimg0.ibsrv.net/gimg/www.jaguarforums.com-vbulletin/1024x575/80-dscf0777_zpsifew3shn_37a08d5c1582c36fa5182a8a2dd9abab52401fb1.jpg

 

 

http://cimg5.ibsrv.net/gimg/www.jaguarforums.com-vbulletin/1024x575/80-dscf0778_zpsp9ohyo70_0fd8b9eced97a3c13fba1bc3a70b93f0f33dc6eb.jpg

 

And tack welded in

 

http://cimg2.ibsrv.net/gimg/www.jaguarforums.com-vbulletin/1024x575/80-dscf0781_zps7kb0wxed_679afe5d9ab9e5f925a5f52eedb89b1bd687c1db.jpg

 

 

http://cimg6.ibsrv.net/gimg/www.jaguarforums.com-vbulletin/1024x575/80-dscf0783_zpsqfkelksx_c79e92ad2b10ef0772ef11bde8bf4dc5fd83406e.jpg

 

And ran out of energy!!  Until tomorrow.

 

Andy.

[andyfanshawe]

Does it only allow 10 photos to be hyperlinked in one post?

 

May repost the last bit so if anyone is too idle to click on the link,here the photos are!!

 

Here is the area cut out and the panel behind media blasted and painted with kurust

 

 

Ive left the lower lip in to make sure I know where the panels line up.

 

Cardboard templates made to mimic the original panels.  ie in 2 sections spot welded together

 

 

 

And cutout and spotwelded together with my trust spot welder

 

 

And tack welded in

 

 

And ran out of energy!!  Until tomorrow.

 

Andy.

[Old Peter]

Downloading Photos, Andy, seems to have rules of its own.

 

Sometimes I can, and sometimes it tells me that the file is too big.

 

I will love it one day.

 

Peter.

[Claws]

Makes my Radiator Grille change look like a stroll in the park! are you clocking up your man hours on this?

Just like Peter said will be following this with interest

 

Steve

[Russ68]

I'm a bit scared to look under the sill covers now :s

[andyfanshawe]

Hi Steve and Russ68.

 

Dont look under the covers!  I did that once and look at the mess I'm in now!!!

 

Ill take it steady with the pictures.....

 

Today was weld up the steel that I had fabricated and make the bottom horizontal plate.  This one.

 

 And after 3 hours, here it is!

 

 

 

As you can probably tell Ive welded on a right angle flange to keep the strength in that area when someone uses a jack there.

 

Weld that in tomorrow after painting iut on the inside with etch primer and blue paint.

 

Speaking of blue paint, the inside of the cavity was prepped, etch primed and painted blue.  Looks good even though no-one will see it, and it will be covered in dinitrol 3125 anyway!

 

 

 

Even more welding to do tomorrow then, but at least it will be pretty in blue!

 

Andy.

[Paul888]

Nice work had similar issues myself ..

[Wessex]

Hi Andy, looks like something off of the Mike Brewer/Ed China show.

I envy your skills and fearless approach. Had a conversation recently with a guy I've bought a couple of things from and his theory is that these areas are left unprotected on purpose to limit the life of jaguars. I think he had a point because Mondeos don't seem to have this rust problem or any other make over the last 15-20 years.