Front floor-pan query

[mat_stoke]

I have a 1993 facelift 4.0 (AJ6) XJS coupe and the MOT noted that the front floor-pans are rusting. I can source replacement front floor-pans for the pre-facelift car but I do not think they are suitable for mine. Does anyone know if replacement floor-pans are available for the facelift XJS coupe or do I just need to find a good welder/fabricator to cur out the rust and weld-in sheet metal?

Thanks in advance

[steve_m]

It depends how corroded it is and where it is.
If it is around the floor and sill/gearbox tunnel joints then it is a huge job.
If it is just patchy in the middle then just cut out and replace with new metal.
I don't know about new floor pan availability.
I had a similar problem with my first car, 1966 MGB Roadster.
Solved it by cutting a slab out of the side of an old washing machine, drilling it and riveting it to the good metal and slapping on several layers of underseal.
Sailed through the MOT.
Obviously now that I am older I wouldn't dream of doing such a thing; I'd use modern mastics and rivets, just like Jaguar do.

[RichardSEL]

Dunno what these "modern mastics" are that'll work with steel...

Just been thru this with my Owen Sedanca (XJ6 series 1 chassis but tubular frame and ally body)
Parked underneath a tree for many years forgotten. And so half rotted thru
The workshop that did the floor pans got original items, and cross members too. There is some strength in the corrugation. Any classic car enthusiast planning on laying out "real" classic car money would want to see those. And in the docs too.
Seam welds throughout -- MOT testers (although Owen's now not needing MOT) are alert to just tacks or spot welds. Some even fail on outer sills being only tacked as well.

[davidr]

Have you tried Martin Robey?