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This is the story of PHU41R continued from: viewtopic.php?f=45&t=12285&p=66758#p66758

Here's the rear suspension just after removing:
and the front and back:
and the front

The IRS was stripped easily enough and the frame sent for power coating. This is in good condition. Seen here with the one off my E-type, also powder coated at the same time.
I also decided to clean up the hubs and do the rear bearing, also at the same time as doing the E-type ones as I had borrowed the special tool off someone.

Here's one hub cleaned, the other still to do.


and the special tool in use....

...and the end float checked:
Next, was on to the front suspension. This is where the problems started:

Here's some of it in Airfix mode:

The first sub frame - the original one to the car - was too badly corroded to be able to use it and one of the fulcrum shaft was seized in.

This is the side that came out:
This is what it looks like now (you might just be able to see the end of the fulcrum shaft):
Sub frame No. 2 is behind it. Also, note the patch welded to the sub frame No. 1. This was presumably done a long time ago.

This is the best picture I have of sub frame No. 2 before disassembly:

Unfortunately I paid quite a lot of money for this subframe (complete with all suspension components and steering rack and also paid a hefty price to get it moved up to Scotland. It appeared in reasonable condition:

.....but once stripped, it was apparent that it had been badly repaired. The metal used for repair was coke can thin and there even appeared to body filler disguising the repair.

Here's the worst repair: and the same area with the repair metal removed: Once shot blasted, other holes and repairs became apparent too. So this was a no-go.

Here's that same area of damage with the bad metal reduced back:
Luckily, I got hold of a third sub frame from a fellow club member in Aberdeen. This one was originally off a XJ6 S1 2.8 and although there was surface rust from sitting around for a long time in his garage, it turned out to be pretty solid.

Here it is before blasting, next to sub frame No. 2: and here it is after Powder Coating:

Continued at: viewtopic.php?f=42&t=12287

Nice work, Roger.

Quite a struggle for you. Nice workshop facilities. Keep at it, Pal.

Mike

Well done Roger,

I love seeing pics of components before and after!

Paul

Great stuff Roger - I feel another magazine article coming on!

David,

Thanks. And thanks too to Paul and Mike. I can either condense these latest posts into a magazine article or I thought I could do a post/article on all the places I've found significant corrosion on the car. I feel this could be useful to other XJ-S owners as so much of what I have found is concealed behind trim and shielding etc. What do you think?

Cheers
Roger