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'92 Sovereign: Rust and restoration

Rory
Posts: 6098
Joined: Sun Nov 22, 2009 8:50 pm
Location: Herne Bay, Kent

Re: '92 Sovereign: Rust and restoration

Postby Rory » Thu Mar 01, 2012 10:24 am

Glad it is all going so well. and not as bad as you feared- quite i relief :D
lok forward to seeing you both in the summer...my engine bay is still no further on... hmmmmmmm :oops:


rory
1992 4.0 Daimler(662003)(2010-)

drce
Posts: 418
Joined: Tue Jul 28, 2009 5:50 pm
Location: wirral

Re: '92 Sovereign: Rust and restoration

Postby drce » Thu Mar 01, 2012 2:15 pm

Hi Rory - David will put us to shame - even more so this time!
I'll try to get the JEC event on the Sunday - are you going?

david
Posts: 6497
Joined: Wed Aug 06, 2008 8:09 pm
Location: Cheshire, UK

Re: '92 Sovereign: Rust and restoration

Postby david » Sun Mar 04, 2012 5:14 pm

drce wrote:Hi Rory - David will put us to shame - even more so this time!
I'll try to get the JEC event on the Sunday - are you going?



I didn't put anyone to shame last time - my car had holes in it!! :lol:
Image 1992 Sovereign 3.2 diamond blue (1993 model)

naki_k
Super Moderator
Posts: 28834
Joined: Sun Feb 21, 2010 9:25 pm
Location: Kirton, nr Boston, Lincolnshire

Re: '92 Sovereign: Rust and restoration

Postby naki_k » Sun Mar 04, 2012 6:39 pm

david wrote:my car had holes in it!!
..... cunningly disguised!
88 3.6 XJ6 PDH/CEM
90 Range Rover Vogue SE 3.9 V8 LPG
91 4.0 XJ6 Manual
92 4.0 XJR Manual
92 4.0 XJR
93 3.2s - 4.0 Manual conv
93 4.0 Sovereign
93 6.0 XJ81 DD6 x2
93 6.0 XJ81 XJ12
94 4.0 XJR
94 4.0 Daimler
96 4.0 X306 XJR
96 4.0 X300 D6
97 4.0 X300 Sport Manual
2000 LR Discovery ES TD5 A
Breaking 40/ 300

david
Posts: 6497
Joined: Wed Aug 06, 2008 8:09 pm
Location: Cheshire, UK

Re: '92 Sovereign: Rust and restoration

Postby david » Sat Mar 31, 2012 11:21 pm

Some more rust and rehabilitation pictures!

More complete photographs of the right side sill end reconstruction, apologies for any repetition:

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Rusty metal cut out:

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New metal parts shaped:

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Then welded in:

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The bulkhead wasn’t bad on my car, mainly having rust in a central part near the earth point. Thankfully, the inner bulkhead wasn’t rusty so only needed to be cleaned up a bit. Rust through the inner bulkhead complicates the job considerably because of the huge array of internal parts which need to be removed in order to get to its inner face. The whole climate control system which involves removing both the heater matrix and air conditioning evaporator along with all their allied pipes and electronics need to come out. I was very glad my car didn’t need this!!

The bulkhead rust blister is visible here. I first noticed rust here in the late 1990s – it has developed very slowly since.

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Cut!!

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Repair section cut from repair section – a genuine Jaguar part I was lucky to find.

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Welded in:

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Another Jaguar part was used for the plenum top repair section, cut from a ‘Windscreen panel’ FNA1114BC, part 3 in the diagram:

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Very accurate cutting saw it fit perfectly:

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Spot welded in:

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Then the welds ground off:

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More in a minute!!

David
Image 1992 Sovereign 3.2 diamond blue (1993 model)

david
Posts: 6497
Joined: Wed Aug 06, 2008 8:09 pm
Location: Cheshire, UK

Re: '92 Sovereign: Rust and restoration

Postby david » Sun Apr 01, 2012 12:06 am

The top of the right hand inner wing was badly rusted. These were built up from several overlaid metal pieces by Jaguar in the XJ40’s original construction. Gray built up the layers in an identical way when he reconstructed them.

With the rusty plenum top removed, this was revealed:

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Luckily, the brown staining is dust not rust and was successfully vacuumed!

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First layer built up. I seem to have lost the ‘cut out’ photo!

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Sprayed with zinc:

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Next layer shaped and fitted:

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With side piece tacked on now:

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Welded:

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Welds are ground down in preparation for the next layer:

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And zinc sprayed again:

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Final layer is the plenum top:

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The same work was also done on the left side. If anything, the rust was probably worse on this side.

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Here you can see how the rust coloured staining is dust.

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All welded then dressed with a grinder:

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Final layer is again the plenum top:

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Image 1992 Sovereign 3.2 diamond blue (1993 model)

Jaguarsport
Posts: 4903
Joined: Wed Jun 10, 2009 1:52 pm
Location: Bedfordshire, England

Re: '92 Sovereign: Rust and restoration

Postby Jaguarsport » Sun Apr 01, 2012 12:08 am

Looks to be coming on very nicely, excellent repair work.
http://www.jaguarxj40project.blogspot.com/
Alfa Romeo 159 Lusso 1.9 jtdm ('07)
BMW 120d Sport ('07)
Mazda MX6 2.5 V6 ('97)

old del boy
Posts: 6871
Joined: Thu Jul 10, 2008 9:29 am
Location: Kent

Re: '92 Sovereign: Rust and restoration

Postby old del boy » Sun Apr 01, 2012 12:20 am

Wow , just WOW , that is some accurate restoration work and very thorough too , i particularly like the newly fabricated sill end cap , how do they do that :?

I think you're getting body restoration usually reserved for far more expensive exotica , i can only wish you luck with the final bill ;)

Derek..
'93 4.0L Daimler, solent blue,
'93 4.0L Daimler, Westminster,
'85 2600 Rover sd1 vdp oporto.

david
Posts: 6497
Joined: Wed Aug 06, 2008 8:09 pm
Location: Cheshire, UK

Re: '92 Sovereign: Rust and restoration

Postby david » Sun Apr 01, 2012 12:44 am

old del boy wrote:Wow , just WOW , that is some accurate restoration work and very thorough too , i particularly like the newly fabricated sill end cap , how do they do that :?

I think you're getting body restoration usually reserved for far more expensive exotica , i can only wish you luck with the final bill ;)

Derek..


The guys do work on some expensive cars but they're not expensive ( hopefully :shock: :lol: ). I'm really impressed with the way everything fits on the car; the front wings seem to fit better than they did originally and the bulkhead/plenum and rear deck panel really are perfect. Gray is good.

David
Image 1992 Sovereign 3.2 diamond blue (1993 model)

xjr-ant
Posts: 2552
Joined: Sat Jul 12, 2008 2:56 pm
Location: East Sussex

Re: '92 Sovereign: Rust and restoration

Postby xjr-ant » Sun Apr 01, 2012 12:44 am

Fantastic work there i think. I wouldn't hesitate to send my car there unlike other places. Quality of work looks top notch. Good luck with everything David - Not that you will need it though!
Various XJ40's and one X300.