Rear screen pillar rust repair

Rusted holes in several places due to the padding behind it getting wet.
Awkward shape in that it curves in several dimensions. 

Started by making a mould of the shape with body filler 
using masking tape to stop it sticking to the metal

Cut the sheet metal and folded an edge on it then
started to shape it with a shrinker/stretcher 

First of many trial fits

Nearly there!

Butt welded after cutting out the exact matching shape

Fully welded ready for grinding smooth

Ground flat and ready for lead loading

Leaded and filed ready for primer

Finished and trying to decide on a colour

Rear Valance

 

   

Panels back from stripping and coating

 

Nearside sill and floor repairs

Lead Loading

 

All the panel joints on Jaguars up until the 1980’s were lead filled so all mine will be the same. Unlike body filler, lead won’t crack or fall off it’s bumped.

Rear Wings - not a pretty sight

 

More filler than steel and hard to tell what the correct shape was or how the spats are attached.

   

For racing the boot was sealed off with sheet aluminium and any remaining gaps were filled with expanding foam

The fuel tank covers were panelled over with aluminium
 so looked a bit better than they really were.

 

The panels under the fuel tanks couldn’t be repaired but since my fuel tank is from an XJS I didn’t need exact copies so could make panels without the drain holes. 

    

Part way through the repairs, this is the view above and below.