Xjs floor pan

[algreen06agg990]

Hello all

If anyone has had to repair the floor on their xjs I could really appreciate some advice.

What thickness of mild steel would you recommend? I was thinking around 1.2mm. I don’t want to use the wrong grade of material.

Thanks for any support.

Kind regards
Al

[almcl]

Just been and looked at my left-over steel sheet from the last floor repair and it appears to be 20 gauge (.035" / 0.9 mm) but 1.2 mm (which is close to 18 gauge/0.049") should be fine.

The only thing I would say is that if your welding skills are like mine, having a big mismatch in thickness between repair patch and original can make not burning holes in the original a bit more tricky.

[poprivet]

Hi Algreen, I don't know about the thickness but a gentle reminder for anyone reading this to be aware of the petrol lines and underseal attached underneath before welding.

The only places mine had minor perforations were the join between the floor and the transmission tunnel and on one of the seatbelt mounts. That was a very long time ago and subsequent waxoyl/underseal has stopped any further corrosion.

If you can attach some photos and a description I'm sure it will be of interest.

[algreen06agg990]

Thanks for your replies they are most welcome. I may well post some photos after completing the repair. Fingers crossed it all goes to plan!
Kind Regards Al

[algreen06agg990]

Hello

I have included a couple of photos showing my floor. Any suggestions on the beat way to proceed are most welcome.

Driver side front

Behind driver seat

[almcl]

It looks as though both images are of the same area - driver's floor?

Cut out all the rust on the sloping panel as straight as possible. Make a buck to match the shape of the indentations and press a repair section. A fly press helps, if you have access to one, but I had some success with G clamps.

The inner sill looks a bit more challenging and a good deal more cutting may be required before the full extent becomes apparent. It also looks as though the floor may have been repaired in the past? If so, it might be a good idea to remove the finish to see exactly what has been done.

The rot may go as far as the A post. If it does, taking off the door may be a good idea and bracing the opening before applying heat could help. From memory (it's been 30+ years since I last did a Jaguar sill/floor repair) the inner and outer sill joint is is a triple sandwich with the floor pan and was secured at the factory by spot welds but if you don't have access to a spot welder (they can be hired), plug welds at the same intervals will work.

Good luck with it and take LOTS of photos!

[ptjs1]

Al,

I'd politely suggest that looks quite significant and is I'd really be looking further at inner and outer sill and into the A-post.

You really need to strip back the floors, sills etc and fully assess the extent of that corrosion before starting any remedial activity.

Good luck

Paul

[algreen06agg990]

Thanks for your help guys.

Yes I think some more metal will have to be removed to access what’s going on.

I love the car so I guess there is only one approach and that is to very carefully get on with it. Toe board first then sills.

The funny thing is it’s only the driver side that has suffered, the passenger side is sound. At least it’s only one side to worry about for now!

Kind regards
Al

[ptjs1]

Al,

Just be aware that cutting out the toe-board may actually help you get to the sills & A-post.

Cheers

Paul

[FGARDEN]

Hello all

If anyone has had to repair the floor on their xjs I could really appreciate some advice.

What thickness of mild steel would you recommend? I was thinking around 1.2mm. I don’t want to use the wrong grade of material.

Thanks for any support.

Kind regards
Al
[/Buy a Replacement Floor Panel online. I have a Floor Panel for Passenger Side Jaguar XJS £60.00]