Rust repairs to rear wheel arch in progress

[poprivet]

Since the XJS has been off the road I thought I would take advantage of tidying some of the bodywork problems. Those who know my car will be aware that it wasn't in the best condition when I bought it 13 years ago having at least seven previous uncaring owners. No surprise therefore that the body had rotted in all the usual places. A good few cans of Waxoyl stopped any further rot at that point, but of course would do nothing for the corrosion already present. Luckily at that time, only the thinner metalwork was affected and not the structural steel work. I have been completing an annual ritual of rubbing down, filling and painting the worst areas ever since. The thing is that I never expected to own this car so long, I knew from the off it was rough but I just wanted to experience the XJS phenomenon. As the years passed it grew on me to the point where it will now be with me for life. I would love to be in a position to have a professional restoration and full respray but I'm not, so there we are, what can you do. I have always driven this car in any weather condition and at any time of the year. Its been to the Outer Hebrides, Lands-End and just about everywhere else in Britain through snow, rain and salt and I have no intention to change.

I will add right here that although I'm pretty handy with mechanical maintenance, I'm no expert in body repairs, so for one thing this isn't a 'how to do it article' and if you find fault with my way of working, fine. Go do it your way but don't moan at me, thank you.

This sequence of photos concentrate on the R/H lower rear wing section in front of the wheel arch above the sill. I've picked this as it is in the worst condition of the repairs I am tackling. The first picture shows it before any remedial work, lots of XJSs look like this, doesn't look too bad from a distance, but what lurks below?. This area suffers because on the inside, which is below the rear laud speaker has foam rubber stuffed into it to reduce drumming. It also holds condensation and moisture and is a lovely place for rust to eat its way out. Luckily the sill was structurally unaffected in my case, although I have seen other cars where the whole damn thing has disappeared.

You can click on any of the photos to make them larger, although it's not a pretty sight!

http://www.jec-xjs-forum.org.uk/xjsbb2/ ... 7-1_tn.jpg

After attacking the area with angle grinder, pry-bar and flap-wheel, all the previous filler and rust has gone and the extent of the damage can be seen. The purple stuff is the Comma rust killer which has been liberally applied to any bare metal.

http://www.jec-xjs-forum.org.uk/xjsbb2/ ... 7-2_tn.jpg

Fresh steel was then mig-welded in to provide a permanent fill. At the point when this photo was taken, not all the welding was complete so it still looks rough.

http://www.jec-xjs-forum.org.uk/xjsbb2/ ... 7-3_tn.jpg

After all the metal was replaced, and painted with rust-stop, body filler was built up to match the contours of the original. This exercise takes considerable time to get right. Multiple curves and surfaces are needed. Don't worry about the inside bit, at the very end, fresh Waxoyl was pressure sprayed over the entire area.

http://www.jec-xjs-forum.org.uk/xjsbb2/ ... 7-4_tn.jpg

This photo shows the area after the initial primer coat. Not yet perfect, a bit more filling and rubbing down to do but its coming along.

http://www.jec-xjs-forum.org.uk/xjsbb2/ ... 7-5_tn.jpg

The top coats, this is where it gets difficult. I have no access to any decent spray equipment or paint. All the spray cans are nasty acrylic ones in the wrong shade. Even Halfords can't help with their mix-a-can service as Jaguar Glacier White contains chrome yellow or some such which is now a banned substance apparently. Luckily for me, Rover Glacier White and Vauxhall Glacier White are a decent match. They are subtly different but my paint is so faded and varies from one end to the other one or the other seems to do. Not perfect of course, but does the job. A number of coats later and finished with a clear lacquer the end result is acceptable for me.

http://www.jec-xjs-forum.org.uk/xjsbb2/ ... 7-6_tn.jpg

Plenty more areas to tackle, but with the cold and damp weather approaching its not a good time of the year for painting, so it will likely have to wait until spring.

[Brakebuster]

nice job there POP ,

its a good feeling to do this sort of work, knowing your taking care of the car

BB

[dhdove]

Pop

That's a huge improvement, congrats!

Tony

[chris211083]

nice to see another getting the treatment it needs!!! good job!!!

[masterb]

Wish i had took some pics off my rear arch repair, and some of the other jobs i have done.
Going to keep my old digi camera in garage i think, rather than it gathering dust in the drawer.
Cant remember if i posted any pics i took of my gearbox refillling, and leaky speed sensor thingy job?
Going to do a bit more body work this week hopefully.
Its bloody difficult trying to match old paint.

[jaydev]

Nice Job!