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XJ40 4.0 re-birth.

Jaguarxj40
Snr Member
Posts: 296
Joined: Wed Jul 12, 2017 3:53 pm
Location: Pagam West Sussex

Re: XJ40 4.0 re-birth.

Postby Jaguarxj40 » Sat Nov 17, 2018 10:36 am

Aidan wrote:Very professional looking boot infill panels there, Gary. We expect no less from you :) .
But how did you make the little clips that hold them in place... weld them onto the metal surrounding the holes?


Hi Aidan,
Thank you, the clips are automotive cable run clips that are a sort of a flat S shape that you would not normally see as they would be hidden behind panels in the car. I thought of all sorts of ways to fix these but the recess lip is so narrow I didn't want to over complicate it so this was a compromise, normally these clips have some sort of a galvanised finish and as they would be visible I painted them in body colour.

naki_k wrote:Very nice. Why they did not fit a cover on these pre 93 cars i don't know.

Did you check the little switch, on the RH hinge. They can break in various ways.


Hi Naki,

Thank you, you know that I can't stop doing things like this ;) yes it's very annoying that being such a lovely car they skimped on that last little bit of trim, however not that I noticed it before until I decided to tidy this area up but there are a series of square holes around the edge of the boot that can be seen in the picture, this not my original boot, I took this off another car in my local scrap yard so maybe this was off a post 93 car that would have had the full boot lining :?:

Ah yes, the boot light, I was going to mention this but you beat me to it :D

This was a real annoyance to me, with a multi meter I checked all wiring and could not find any issue at all, it couldn't be the switch surely, it's such a simple thing, right :roll:

I brought a new plunger switch from Halfords as genuine switches are ridiculously expensive and with the intention of adapting a bracket to make it work.

However, once I had wrestled (what a pig these mounting screws are to get at to remove this switch) the switch off, even though it's a non sevicable part I could see that there was a way in to disassemble it.
Nothing to loose, I took it apart carefully, the contact points were a little oxidised, cleaned up all contacts, tweaked both springs and a little silicon lubricant on the moving plunger, reassembled and hey presto a working light again :D

Gary.
Current
1996 BMW Z3
1990 Jaguar XJ40 4.0

Previous,in this order.
1986 BMW M535i
1985 BMW 525e
1972 Vauxhall victor FE2300
1966 Ford cortina estate
1961 Renault dauphine Gordini
1978 Range Rover
1976 LR 101 forward control
1968 S2 lightweight Land Rover
1975 Range Rover
1973 Range Rover
1972 series 3 Land Rover SWB

katar83
Posts: 2728
Joined: Tue Aug 23, 2011 11:17 am
Location: Cambridge

Re: XJ40 4.0 re-birth.

Postby katar83 » Sun Nov 18, 2018 10:12 pm

If you ever get to removing the rear a-frame here's a worst case scenario. Naki recently supplied me with a spare a-frame which must have came from a sunken 40 as it was very rusty and both bolts next to the bush were proper seized solid and completely rusted. On one side even the large spacer was completely seized and of course both bolts snapped maybe 3cm above the hole.

Image

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The only way to remove it is to either drill it out or clean the bolt with a wire brush and weld a nut and then undo it. If these two come out fine(on mine one came out easily, the other snapped) then the rest is a breeze and its an easy job, if they don't then its best to be prepared for the worst or leave it as is :)
1997, 4.0 LWB X300 - Unlucky car but still a daily driver.
1988, 3.6S XJS - Never ending restoration project.
1994, 3.2S X300 - Accident damaged, October 2015. Gone!
1994, 3.2S XJ40 - Long gone.

Jaguarxj40
Snr Member
Posts: 296
Joined: Wed Jul 12, 2017 3:53 pm
Location: Pagam West Sussex

Re: XJ40 4.0 re-birth.

Postby Jaguarxj40 » Fri Nov 30, 2018 11:02 am

katar83 wrote:If you ever get to removing the rear a-frame here's a worst case scenario. Naki recently supplied me with a spare a-frame which must have came from a sunken 40 as it was very rusty and both bolts next to the bush were proper seized solid and completely rusted. On one side even the large spacer was completely seized and of course both bolts snapped maybe 3cm above the hole.



The only way to remove it is to either drill it out or clean the bolt with a wire brush and weld a nut and then undo it. If these two come out fine(on mine one came out easily, the other snapped) then the rest is a breeze and its an easy job, if they don't then its best to be prepared for the worst or leave it as is :)


Hi Katar83,

Thank you as ever for you're help and guidance and picture sequence, it's always good to know of any pitfalls before this job is next on the car bucket list.

Gary.
Current
1996 BMW Z3
1990 Jaguar XJ40 4.0

Previous,in this order.
1986 BMW M535i
1985 BMW 525e
1972 Vauxhall victor FE2300
1966 Ford cortina estate
1961 Renault dauphine Gordini
1978 Range Rover
1976 LR 101 forward control
1968 S2 lightweight Land Rover
1975 Range Rover
1973 Range Rover
1972 series 3 Land Rover SWB

Beavis
Posts: 49
Joined: Sun May 07, 2017 7:39 pm

Re: XJ40 4.0 re-birth.

Postby Beavis » Wed Dec 05, 2018 5:32 pm

I'm about 10 pages behind in your adventure but wanted to say; awesome job on the respray and the interior. As someone that's tackled a couple of small leather covering jobs I doff my cap to your talent, particularly the dash.. much patience required there! I'm sure as I catch up on the other pages i'll see more great work too...

katar83
Posts: 2728
Joined: Tue Aug 23, 2011 11:17 am
Location: Cambridge

Re: XJ40 4.0 re-birth.

Postby katar83 » Sun Feb 17, 2019 1:21 pm

Jaguarxj40 wrote:(...)
Hi Katar83,

Thank you as ever for you're help and guidance and picture sequence, it's always good to know of any pitfalls before this job is next on the car bucket list.

Gary.


Finished derusting my sunken frame.

Image

Had to do it in two stages as too big for any container I had so one side was derusting for 8 hours yesterday during day and then the other overnight, I just turn it around and went to bed :)

Came out great

Image

Image

This was cleaned up using electrolysis. Not a spec of rust now on it, but lots at the bottom of the Jaguar XJS boot liner. Just washed it in some clean water and waiting for flash rust to appear, then I'll paint it Vactan and then something more thick and lasting 8-)
1997, 4.0 LWB X300 - Unlucky car but still a daily driver.
1988, 3.6S XJS - Never ending restoration project.
1994, 3.2S X300 - Accident damaged, October 2015. Gone!
1994, 3.2S XJ40 - Long gone.

Jaguarxj40
Snr Member
Posts: 296
Joined: Wed Jul 12, 2017 3:53 pm
Location: Pagam West Sussex

Re: XJ40 4.0 re-birth.

Postby Jaguarxj40 » Wed May 01, 2019 8:49 pm

Hi All.
I'm still here. Sorry for not posting in some considerable time but heath issues have kept me out of the garage due to having two wound infections post gall bladder removal which put me off work for six weeks in December and no manual work for another six weeks after that and to cap it all while is was recuperating the arthritis in both of my knees which was so bad that i could barely walk without considerable pain and currently I'm walking with one stick, i should have had treatment for this last week but it was cancelled :evil: .

My plan to get the Jag on the road by this May has well and truly been blown, I've got to the point regardless of the pain that i need to press on and get the last biggest part of the re-birth finished.

The rear passenger wing has not been painted as i had put off replacing the crusty wheel arch. Two weeks ago i decided to press on with this so i can get the last of the painting done.

I seem to have lost some pictures but i have cut out the arch and welded in the replacement panel.

This was after the welding had been completed and welds dressed back and the first skim of filler sanded back.

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This was the result of another couple of skims of filler and sanding back, no wet sanding has taken place at this stage,

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There is still a lot of prep to get it just right before spraying but I'm nearly there :D

While i was at it i have sprayed the wheel centres, i was able to do one wheel at the time on my work bench in my man cave to i could sit down rather than standing.

They are a bit early 2000 style but i like them, Mrs L is not that keen, hopefully the colour will grow on her, if not they will have to be re-sprayed back to a grey-ish silver. lets see, i suppose the gunmetal grey colour is not going to be everyone's choice :?

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Regards
Gary.
Current
1996 BMW Z3
1990 Jaguar XJ40 4.0

Previous,in this order.
1986 BMW M535i
1985 BMW 525e
1972 Vauxhall victor FE2300
1966 Ford cortina estate
1961 Renault dauphine Gordini
1978 Range Rover
1976 LR 101 forward control
1968 S2 lightweight Land Rover
1975 Range Rover
1973 Range Rover
1972 series 3 Land Rover SWB

katar83
Posts: 2728
Joined: Tue Aug 23, 2011 11:17 am
Location: Cambridge

Re: XJ40 4.0 re-birth.

Postby katar83 » Wed May 01, 2019 10:45 pm

Amazing work Gary! Please do tell more, about the arch, I just bought the panel for mine and planning to do exactly what you did when it gets warmer. How did you weld the inner panel? I assume the lip rusted away so no joining there and just pushed forward and spot welded to the back of the arch? That's how I plan to do mine, as joining both at that lip is what got it rusted in the first place.
Were there many spot welds around the door area? What spot weld drill did you use? Did you weld continuously around entire panel or joined? Plug welded? Lap or butt joint? Lots of grinding afterwards? Any other paint/primer protection at the back, etc? Took long to get the filler right? How are you planning to paint it now? Please give as much details as possible! :lol:
1997, 4.0 LWB X300 - Unlucky car but still a daily driver.
1988, 3.6S XJS - Never ending restoration project.
1994, 3.2S X300 - Accident damaged, October 2015. Gone!
1994, 3.2S XJ40 - Long gone.

Elsa_jag
Posts: 1217
Joined: Wed Dec 30, 2009 10:12 pm
Location: Hunnington, West Midlands

Re: XJ40 4.0 re-birth.

Postby Elsa_jag » Thu May 02, 2019 11:44 am

Nice update. Sorry to read that your health has hindered the project so much!

I do look forward to seeing the car in the flesh one of the days!

And, for what it’s worth, I really like those wheels and the gunmetal colour! They look smart, the car is an ‘80’s / 90’s car so the slightly retro look works well!
Regards, Carl

ImageImage
Elsa_1994 3.2 s/ 61000 miles/ VIN 698892
http://xj40.com/viewtopic.php?f=33&t=1195

Jaguarxj40
Snr Member
Posts: 296
Joined: Wed Jul 12, 2017 3:53 pm
Location: Pagam West Sussex

Re: XJ40 4.0 re-birth.

Postby Jaguarxj40 » Thu May 02, 2019 10:50 pm

katar83 wrote:Amazing work Gary! Please do tell more, about the arch, I just bought the panel for mine and planning to do exactly what you did when it gets warmer. How did you weld the inner panel? I assume the lip rusted away so no joining there and just pushed forward and spot welded to the back of the arch? That's how I plan to do mine, as joining both at that lip is what got it rusted in the first place.
Were there many spot welds around the door area? What spot weld drill did you use? Did you weld continuously around entire panel or joined? Plug welded? Lap or butt joint? Lots of grinding afterwards? Any other paint/primer protection at the back, etc? Took long to get the filler right? How are you planning to paint it now? Please give as much details as possible! :lol:


Hi Katar,
thank you and its great that I'm able to hopefully be abled to pass tips onto you as I'm always in awe of work that you do :D

I'll try to answer your questions as best i can.

Firstly i am blessed with a very rust free Jag, this is the only welding this car has needed. I know this well as i brought it as a 11 year old car, OK i have replaced the front wings and boot lid as the originals were a bit bubbly.

Anyway, the rear arch in question was not very rusty, more a bit scabby so the outer lip was more rust damaged that the inner arch which i only discovered once i cut the outer off. The repair panel has a lot more metal on it than i needed to make this repair.
The first thing i did was to mark my cut area with a marker as i have illustrated in the picture below. i made my cut all the way around the arch then it was a case of finding the spot welds on the return lip which i think was about 10 or 12, i used a normal drill bit, didn't bother with the spot weld drill.

Once i had done this i was able to peal off the outer arch, then it was a case of trimming the repair panel to fit what i had cut off with some fettling here and there. When i had the size repair panel that i wanted the outer edge of the repair panel needed to be able to slip inside of the wing but you need to joggle the outer edge of the repair panel inwards (put a step in it most of the way around until i got to the inner door lip part) so you end up with a flush finish between the repair panel and the original wing
The inner door closing joint i made as a butt join.

Once it was all lined up i was able to start welding but not as a continuous weld as this will create massive distortion due to the heat generated so i just spot welded at intervals until was all joined up, then it was a case of grinding back until flush then the filling and sanding begins until you get to a point where the repair is invisible and can be painted.

My inner arch was mostly intact and only needed local repair to make good to accept the new outer arch replacement. My joggling tool has a hole punch function so before i fitted the repair panel i punched about 10 holes in the inner lip and after i welded the arch in place it was just a case of filling the holes up with weld into the inner arch then grinding back to make flush.

To date i have filled and rubbed back 3 times to get the profile that i am happy with and i am now at the stage where i will be doing the final finessing before final painting. I think that i have spent about 5 hours filling and rubbing down to date on this repair.

I have used rust proofing in between panels before welding and after to the inner wheel arch sections. I will also be spraying wax oil down inside the wheel arch from inside the boot and through the trim hole in the door shut.

The painting process will be in a little while and i will post back then when i do it.

I hope this all makes sense but please send the questions in if i have not quite explained it right :?

Image
Last edited by Jaguarxj40 on Fri May 03, 2019 3:59 pm, edited 1 time in total.
Current
1996 BMW Z3
1990 Jaguar XJ40 4.0

Previous,in this order.
1986 BMW M535i
1985 BMW 525e
1972 Vauxhall victor FE2300
1966 Ford cortina estate
1961 Renault dauphine Gordini
1978 Range Rover
1976 LR 101 forward control
1968 S2 lightweight Land Rover
1975 Range Rover
1973 Range Rover
1972 series 3 Land Rover SWB

Jaguarxj40
Snr Member
Posts: 296
Joined: Wed Jul 12, 2017 3:53 pm
Location: Pagam West Sussex

Re: XJ40 4.0 re-birth.

Postby Jaguarxj40 » Thu May 02, 2019 11:09 pm

Elsa_jag wrote:Nice update. Sorry to read that your health has hindered the project so much!

I do look forward to seeing the car in the flesh one of the days!

And, for what it’s worth, I really like those wheels and the gunmetal colour! They look smart, the car is an ‘80’s / 90’s car so the slightly retro look works well!


Hi Carl,

thank you, its old age :lol:
I think we get to a point where we have to push the boundaries and get on with stuff regardless of the pain. I find it hard as i have real difficulty in sitting still for 5 minutes, i have to be doing something or it dives me mad.

My wife says I'm over critical of my own work, the car has turned out quite well but its not perfect but I'm happy with what i have achieved in a single garage. I hope that when the car gets its unveiling hopefully before the season is over it gets a warm welcome with some of its minus points :roll: .

As for the wheels, I'm glad someone else is on my side :P your right, the word i was looking for was retro and i too think it suits the era of the car.
Current
1996 BMW Z3
1990 Jaguar XJ40 4.0

Previous,in this order.
1986 BMW M535i
1985 BMW 525e
1972 Vauxhall victor FE2300
1966 Ford cortina estate
1961 Renault dauphine Gordini
1978 Range Rover
1976 LR 101 forward control
1968 S2 lightweight Land Rover
1975 Range Rover
1973 Range Rover
1972 series 3 Land Rover SWB