{"id":1497,"date":"2017-04-30T18:09:51","date_gmt":"2017-04-30T22:09:51","guid":{"rendered":"https:\/\/krissmotors.com\/XJ6\/?p=1497"},"modified":"2017-11-28T17:10:33","modified_gmt":"2017-11-28T22:10:33","slug":"metal-work-assessment","status":"publish","type":"post","link":"https:\/\/krissmotors.com\/XJ6\/2017\/04\/30\/metal-work-assessment\/","title":{"rendered":"Metal repair"},"content":{"rendered":"<div id=\"ez-toc-container\" class=\"ez-toc-v2_0_79_2 counter-hierarchy ez-toc-counter ez-toc-grey ez-toc-container-direction\">\n<p class=\"ez-toc-title\" style=\"cursor:inherit\">Topics<\/p>\n<label for=\"ez-toc-cssicon-toggle-item-69f7f65e18e94\" class=\"ez-toc-cssicon-toggle-label\"><span class=\"\"><span class=\"eztoc-hide\" style=\"display:none;\">Toggle<\/span><span class=\"ez-toc-icon-toggle-span\"><svg style=\"fill: #999;color:#999\" xmlns=\"http:\/\/www.w3.org\/2000\/svg\" class=\"list-377408\" width=\"20px\" height=\"20px\" viewBox=\"0 0 24 24\" fill=\"none\"><path d=\"M6 6H4v2h2V6zm14 0H8v2h12V6zM4 11h2v2H4v-2zm16 0H8v2h12v-2zM4 16h2v2H4v-2zm16 0H8v2h12v-2z\" fill=\"currentColor\"><\/path><\/svg><svg style=\"fill: #999;color:#999\" class=\"arrow-unsorted-368013\" xmlns=\"http:\/\/www.w3.org\/2000\/svg\" width=\"10px\" height=\"10px\" viewBox=\"0 0 24 24\" version=\"1.2\" baseProfile=\"tiny\"><path d=\"M18.2 9.3l-6.2-6.3-6.2 6.3c-.2.2-.3.4-.3.7s.1.5.3.7c.2.2.4.3.7.3h11c.3 0 .5-.1.7-.3.2-.2.3-.5.3-.7s-.1-.5-.3-.7zM5.8 14.7l6.2 6.3 6.2-6.3c.2-.2.3-.5.3-.7s-.1-.5-.3-.7c-.2-.2-.4-.3-.7-.3h-11c-.3 0-.5.1-.7.3-.2.2-.3.5-.3.7s.1.5.3.7z\"\/><\/svg><\/span><\/span><\/label><input type=\"checkbox\"  id=\"ez-toc-cssicon-toggle-item-69f7f65e18e94\"  aria-label=\"Toggle\" \/><nav><ul class='ez-toc-list ez-toc-list-level-1 ' ><li class='ez-toc-page-1 ez-toc-heading-level-2'><a class=\"ez-toc-link ez-toc-heading-1\" href=\"https:\/\/krissmotors.com\/XJ6\/2017\/04\/30\/metal-work-assessment\/#Frame\" >Frame<\/a><ul class='ez-toc-list-level-3' ><li class='ez-toc-heading-level-3'><a class=\"ez-toc-link ez-toc-heading-2\" href=\"https:\/\/krissmotors.com\/XJ6\/2017\/04\/30\/metal-work-assessment\/#Radiator_crossmember\" >Radiator crossmember<\/a><ul class='ez-toc-list-level-4' ><li class='ez-toc-heading-level-4'><a class=\"ez-toc-link ez-toc-heading-3\" href=\"https:\/\/krissmotors.com\/XJ6\/2017\/04\/30\/metal-work-assessment\/#Mitigation\" >Mitigation<\/a><\/li><\/ul><\/li><\/ul><\/li><li class='ez-toc-page-1 ez-toc-heading-level-2'><a class=\"ez-toc-link ez-toc-heading-4\" href=\"https:\/\/krissmotors.com\/XJ6\/2017\/04\/30\/metal-work-assessment\/#Sheet_metal\" >Sheet metal<\/a><ul class='ez-toc-list-level-3' ><li class='ez-toc-heading-level-3'><a class=\"ez-toc-link ez-toc-heading-5\" href=\"https:\/\/krissmotors.com\/XJ6\/2017\/04\/30\/metal-work-assessment\/#Rocker_panels\" >Rocker panels<\/a><ul class='ez-toc-list-level-4' ><li class='ez-toc-heading-level-4'><a class=\"ez-toc-link ez-toc-heading-6\" href=\"https:\/\/krissmotors.com\/XJ6\/2017\/04\/30\/metal-work-assessment\/#Mitigation-2\" >Mitigation<\/a><\/li><\/ul><\/li><li class='ez-toc-page-1 ez-toc-heading-level-3'><a class=\"ez-toc-link ez-toc-heading-7\" href=\"https:\/\/krissmotors.com\/XJ6\/2017\/04\/30\/metal-work-assessment\/#Rocker_panel_end_cap\" >Rocker panel end cap<\/a><ul class='ez-toc-list-level-4' ><li class='ez-toc-heading-level-4'><a class=\"ez-toc-link ez-toc-heading-8\" href=\"https:\/\/krissmotors.com\/XJ6\/2017\/04\/30\/metal-work-assessment\/#Mitigation-3\" >Mitigation<\/a><\/li><\/ul><\/li><li class='ez-toc-page-1 ez-toc-heading-level-3'><a class=\"ez-toc-link ez-toc-heading-9\" href=\"https:\/\/krissmotors.com\/XJ6\/2017\/04\/30\/metal-work-assessment\/#Toe_board\" >Toe board<\/a><ul class='ez-toc-list-level-4' ><li class='ez-toc-heading-level-4'><a class=\"ez-toc-link ez-toc-heading-10\" href=\"https:\/\/krissmotors.com\/XJ6\/2017\/04\/30\/metal-work-assessment\/#Mitigation-4\" >Mitigation<\/a><\/li><\/ul><\/li><li class='ez-toc-page-1 ez-toc-heading-level-3'><a class=\"ez-toc-link ez-toc-heading-11\" href=\"https:\/\/krissmotors.com\/XJ6\/2017\/04\/30\/metal-work-assessment\/#Floor_pans\" >Floor pans<\/a><ul class='ez-toc-list-level-4' ><li class='ez-toc-heading-level-4'><a class=\"ez-toc-link ez-toc-heading-12\" href=\"https:\/\/krissmotors.com\/XJ6\/2017\/04\/30\/metal-work-assessment\/#Mitigation-5\" >Mitigation<\/a><\/li><\/ul><\/li><li class='ez-toc-page-1 ez-toc-heading-level-3'><a class=\"ez-toc-link ez-toc-heading-13\" href=\"https:\/\/krissmotors.com\/XJ6\/2017\/04\/30\/metal-work-assessment\/#Heater_core_corrosion\" >Heater core corrosion<\/a><ul class='ez-toc-list-level-4' ><li class='ez-toc-heading-level-4'><a class=\"ez-toc-link ez-toc-heading-14\" href=\"https:\/\/krissmotors.com\/XJ6\/2017\/04\/30\/metal-work-assessment\/#Mitigation-6\" >Mitigation<\/a><\/li><\/ul><\/li><li class='ez-toc-page-1 ez-toc-heading-level-3'><a class=\"ez-toc-link ez-toc-heading-15\" href=\"https:\/\/krissmotors.com\/XJ6\/2017\/04\/30\/metal-work-assessment\/#Front_trailing_stone_guards\" >Front trailing stone guards<\/a><\/li><\/ul><\/li><\/ul><\/nav><\/div>\n<h2><span class=\"ez-toc-section\" id=\"Frame\"><\/span>Frame<span class=\"ez-toc-section-end\"><\/span><\/h2>\n<p>In general our 1972 XJ6 body and chassis survived in excellent condition. The paint isn&#8217;t original, but the repaint color match is perfect. There are a few surface dings and scratches, but nothing that requires any metal work on the body itself. However, the chassis has several vulnerable points where moisture tends to accumulate over long periods.<\/p>\n<h3><span class=\"ez-toc-section\" id=\"Radiator_crossmember\"><\/span>Radiator crossmember<span class=\"ez-toc-section-end\"><\/span><\/h3>\n<p>The radiator rests on a crossmember that spans between the left and right chassis rails. When rain hits the grille it trickles down through the radiator mesh and puddles at the base of the radiator mount. The two radiator mount holes are not waterproof, so moisture eventually drips down into the hollow crossmember. In our case, rust formed along this bottom portion and also damaged part of the lower valance that covers the crossmember.<\/p>\n<p><a href=\"https:\/\/krissmotors.com\/XJ6\/wp-content\/uploads\/2017\/04\/crossmember-location.png\"><img loading=\"lazy\" decoding=\"async\" src=\"https:\/\/krissmotors.com\/XJ6\/wp-content\/uploads\/2017\/04\/crossmember-location.png\" alt=\"\" width=\"1230\" height=\"849\" class=\"alignnone size-full wp-image-1499\" srcset=\"https:\/\/krissmotors.com\/XJ6\/wp-content\/uploads\/2017\/04\/crossmember-location.png 1230w, https:\/\/krissmotors.com\/XJ6\/wp-content\/uploads\/2017\/04\/crossmember-location-330x228.png 330w, https:\/\/krissmotors.com\/XJ6\/wp-content\/uploads\/2017\/04\/crossmember-location-768x530.png 768w, https:\/\/krissmotors.com\/XJ6\/wp-content\/uploads\/2017\/04\/crossmember-location-1024x707.png 1024w\" sizes=\"auto, (max-width: 1230px) 100vw, 1230px\" \/><\/a><\/p>\n<div id=\"attachment_1832\" style=\"width: 1208px\" class=\"wp-caption alignnone\"><a href=\"https:\/\/krissmotors.com\/XJ6\/wp-content\/uploads\/rusted-xmember.png\"><img loading=\"lazy\" decoding=\"async\" aria-describedby=\"caption-attachment-1832\" src=\"https:\/\/krissmotors.com\/XJ6\/wp-content\/uploads\/rusted-xmember.png\" alt=\"\" width=\"1198\" height=\"163\" class=\"size-full wp-image-1832\" srcset=\"https:\/\/krissmotors.com\/XJ6\/wp-content\/uploads\/rusted-xmember.png 1198w, https:\/\/krissmotors.com\/XJ6\/wp-content\/uploads\/rusted-xmember-330x45.png 330w, https:\/\/krissmotors.com\/XJ6\/wp-content\/uploads\/rusted-xmember-768x104.png 768w, https:\/\/krissmotors.com\/XJ6\/wp-content\/uploads\/rusted-xmember-1024x139.png 1024w\" sizes=\"auto, (max-width: 1198px) 100vw, 1198px\" \/><\/a><p id=\"caption-attachment-1832\" class=\"wp-caption-text\">Rust on inside of radiator crossmember<\/p><\/div>\n<h4><span class=\"ez-toc-section\" id=\"Mitigation\"><\/span>Mitigation<span class=\"ez-toc-section-end\"><\/span><\/h4>\n<p>Happily, the lower crossmember part 12101 (as well as the lower valance piece) remains in stock, so the rusted area was cut out and a new metal piece welded in.<\/p>\n<div id=\"attachment_1830\" style=\"width: 1210px\" class=\"wp-caption alignnone\"><a href=\"https:\/\/krissmotors.com\/XJ6\/wp-content\/uploads\/radiator-xmember-repair.png\"><img loading=\"lazy\" decoding=\"async\" aria-describedby=\"caption-attachment-1830\" src=\"https:\/\/krissmotors.com\/XJ6\/wp-content\/uploads\/radiator-xmember-repair.png\" alt=\"\" width=\"1200\" height=\"512\" class=\"size-full wp-image-1830\" srcset=\"https:\/\/krissmotors.com\/XJ6\/wp-content\/uploads\/radiator-xmember-repair.png 1200w, https:\/\/krissmotors.com\/XJ6\/wp-content\/uploads\/radiator-xmember-repair-330x141.png 330w, https:\/\/krissmotors.com\/XJ6\/wp-content\/uploads\/radiator-xmember-repair-768x328.png 768w, https:\/\/krissmotors.com\/XJ6\/wp-content\/uploads\/radiator-xmember-repair-1024x437.png 1024w\" sizes=\"auto, (max-width: 1200px) 100vw, 1200px\" \/><\/a><p id=\"caption-attachment-1830\" class=\"wp-caption-text\">New radiator crossmember welded in<\/p><\/div>\n<div id=\"attachment_2639\" style=\"width: 1068px\" class=\"wp-caption alignnone\"><a href=\"https:\/\/krissmotors.com\/XJ6\/wp-content\/uploads\/restored-rad-xmember.png\"><img loading=\"lazy\" decoding=\"async\" aria-describedby=\"caption-attachment-2639\" src=\"https:\/\/krissmotors.com\/XJ6\/wp-content\/uploads\/restored-rad-xmember.png\" alt=\"\" width=\"1058\" height=\"455\" class=\"size-full wp-image-2639\" srcset=\"https:\/\/krissmotors.com\/XJ6\/wp-content\/uploads\/restored-rad-xmember.png 1058w, https:\/\/krissmotors.com\/XJ6\/wp-content\/uploads\/restored-rad-xmember-330x142.png 330w, https:\/\/krissmotors.com\/XJ6\/wp-content\/uploads\/restored-rad-xmember-768x330.png 768w, https:\/\/krissmotors.com\/XJ6\/wp-content\/uploads\/restored-rad-xmember-1024x440.png 1024w\" sizes=\"auto, (max-width: 1058px) 100vw, 1058px\" \/><\/a><p id=\"caption-attachment-2639\" class=\"wp-caption-text\">Restored radiator and suspension crossmembers<\/p><\/div>\n<p>&nbsp;<\/p>\n<h2><span class=\"ez-toc-section\" id=\"Sheet_metal\"><\/span>Sheet metal<span class=\"ez-toc-section-end\"><\/span><\/h2>\n<p>Several pieces show pin hole corrosion including the floor pans at the rocker panel &#8220;pinch&#8221; and the front joins around the toe boards.<\/p>\n<div id=\"attachment_2098\" style=\"width: 794px\" class=\"wp-caption alignnone\"><a href=\"https:\/\/krissmotors.com\/XJ6\/wp-content\/uploads\/metal-replacement.png\"><img loading=\"lazy\" decoding=\"async\" aria-describedby=\"caption-attachment-2098\" src=\"https:\/\/krissmotors.com\/XJ6\/wp-content\/uploads\/metal-replacement.png\" alt=\"\" width=\"784\" height=\"555\" class=\"size-full wp-image-2098\" srcset=\"https:\/\/krissmotors.com\/XJ6\/wp-content\/uploads\/metal-replacement.png 784w, https:\/\/krissmotors.com\/XJ6\/wp-content\/uploads\/metal-replacement-330x234.png 330w, https:\/\/krissmotors.com\/XJ6\/wp-content\/uploads\/metal-replacement-768x544.png 768w\" sizes=\"auto, (max-width: 784px) 100vw, 784px\" \/><\/a><p id=\"caption-attachment-2098\" class=\"wp-caption-text\">Interior view of sheet metal replacements<\/p><\/div>\n<h3><span class=\"ez-toc-section\" id=\"Rocker_panels\"><\/span>Rocker panels<span class=\"ez-toc-section-end\"><\/span><\/h3>\n<p>After blasting we discovered that both rocker panels had been previously replaced using a long exterior TIG weld to attach a new lower piece. On the inside, rectangular patch panels were spot welded to the original floor pans. Significant corroded metal along the &#8220;pinch&#8221; seam means the toe boards and floor pans must now be replaced, so a fabricated interior rocker panel piece will be required as well (rocker panel replacement parts are not readily available).<\/p>\n<h4><span class=\"ez-toc-section\" id=\"Mitigation-2\"><\/span>Mitigation<span class=\"ez-toc-section-end\"><\/span><\/h4>\n<p>The XJ6 unibody structure must be repaired with patches that can only approximate the original metal contours. The old repair to the rocker panels further limits what can be done since the old patch must be cut out leaving less of the OEM metal body.<\/p>\n<div id=\"attachment_2112\" style=\"width: 850px\" class=\"wp-caption alignnone\"><a href=\"https:\/\/krissmotors.com\/XJ6\/wp-content\/uploads\/floor-pan-x-sectional.png\"><img loading=\"lazy\" decoding=\"async\" aria-describedby=\"caption-attachment-2112\" src=\"https:\/\/krissmotors.com\/XJ6\/wp-content\/uploads\/floor-pan-x-sectional.png\" alt=\"\" width=\"840\" height=\"654\" class=\"size-full wp-image-2112\" srcset=\"https:\/\/krissmotors.com\/XJ6\/wp-content\/uploads\/floor-pan-x-sectional.png 840w, https:\/\/krissmotors.com\/XJ6\/wp-content\/uploads\/floor-pan-x-sectional-330x257.png 330w, https:\/\/krissmotors.com\/XJ6\/wp-content\/uploads\/floor-pan-x-sectional-768x598.png 768w\" sizes=\"auto, (max-width: 840px) 100vw, 840px\" \/><\/a><p id=\"caption-attachment-2112\" class=\"wp-caption-text\">Floor pan and rocker panel replacement<\/p><\/div>\n<p>A long 18 ga rocker patch panel is joined at the rocker &#8220;pinch&#8221; as well as high on the inside rocker surface. The floor pan will join at a different point than the original unibody, but the new design should be at least as strong.<\/p>\n<div id=\"attachment_2100\" style=\"width: 885px\" class=\"wp-caption alignnone\"><a href=\"https:\/\/krissmotors.com\/XJ6\/wp-content\/uploads\/patch-panel-rocker.png\"><img loading=\"lazy\" decoding=\"async\" aria-describedby=\"caption-attachment-2100\" src=\"https:\/\/krissmotors.com\/XJ6\/wp-content\/uploads\/patch-panel-rocker.png\" alt=\"\" width=\"875\" height=\"307\" class=\"size-full wp-image-2100\" srcset=\"https:\/\/krissmotors.com\/XJ6\/wp-content\/uploads\/patch-panel-rocker.png 875w, https:\/\/krissmotors.com\/XJ6\/wp-content\/uploads\/patch-panel-rocker-330x116.png 330w, https:\/\/krissmotors.com\/XJ6\/wp-content\/uploads\/patch-panel-rocker-768x269.png 768w\" sizes=\"auto, (max-width: 875px) 100vw, 875px\" \/><\/a><p id=\"caption-attachment-2100\" class=\"wp-caption-text\">Fabricated interior rocker panel patch using 18 ga sheet metal<\/p><\/div>\n<p>Jaguar unibody construction only used welds to attach sheet metal pieces since this is quick and inexpensive in an assembly line setting.<\/p>\n<div id=\"attachment_2121\" style=\"width: 172px\" class=\"wp-caption alignleft\"><a href=\"https:\/\/krissmotors.com\/XJ6\/wp-content\/uploads\/Q-rivet.png\"><img loading=\"lazy\" decoding=\"async\" aria-describedby=\"caption-attachment-2121\" src=\"https:\/\/krissmotors.com\/XJ6\/wp-content\/uploads\/Q-rivet.png\" alt=\"\" width=\"162\" height=\"121\" class=\"size-full wp-image-2121\" \/><\/a><p id=\"caption-attachment-2121\" class=\"wp-caption-text\">Q rivet<\/p><\/div>\n<p>Given the location of metal patch repairs, the new fabricated pieces are fastened at the top and bottom with special structural high strength rivets that leave the mandrel in place &#8212; generally known as <em>Q rivets<\/em> &#8212; while the end points are welded to existing metal. <em>Bostik 1100 FS<\/em>, an adhesive sealant, helps make the riveted seams water and rattle proof. Seams are filled with <em>3M\u2122 All-Around Autobody Sealant<\/em> (08500), a white water-based synthetic elastomer that keeps out moisture. Finally, the entire surface is coated with <em>3M\u2122 Professional Grade Rubberized Undercoating<\/em>, a black asphalt-based spray-on that provides sound deadening and anti-rust protection.<\/p>\n<div id=\"attachment_2102\" style=\"width: 933px\" class=\"wp-caption alignnone\"><a href=\"https:\/\/krissmotors.com\/XJ6\/wp-content\/uploads\/repaired-rocker.png\"><img loading=\"lazy\" decoding=\"async\" aria-describedby=\"caption-attachment-2102\" src=\"https:\/\/krissmotors.com\/XJ6\/wp-content\/uploads\/repaired-rocker.png\" alt=\"\" width=\"923\" height=\"316\" class=\"size-full wp-image-2102\" srcset=\"https:\/\/krissmotors.com\/XJ6\/wp-content\/uploads\/repaired-rocker.png 923w, https:\/\/krissmotors.com\/XJ6\/wp-content\/uploads\/repaired-rocker-330x113.png 330w, https:\/\/krissmotors.com\/XJ6\/wp-content\/uploads\/repaired-rocker-768x263.png 768w\" sizes=\"auto, (max-width: 923px) 100vw, 923px\" \/><\/a><p id=\"caption-attachment-2102\" class=\"wp-caption-text\">Riveted and sealed rocker panel patch<\/p><\/div>\n<h3><span class=\"ez-toc-section\" id=\"Rocker_panel_end_cap\"><\/span>Rocker panel end cap<span class=\"ez-toc-section-end\"><\/span><\/h3>\n<p>The rocker panel end caps displayed significant erosion after blasting removed bondo filler.<\/p>\n<div id=\"attachment_2108\" style=\"width: 1352px\" class=\"wp-caption alignnone\"><a href=\"https:\/\/krissmotors.com\/XJ6\/wp-content\/uploads\/END-CAP-@.png\"><img loading=\"lazy\" decoding=\"async\" aria-describedby=\"caption-attachment-2108\" src=\"https:\/\/krissmotors.com\/XJ6\/wp-content\/uploads\/END-CAP-@.png\" alt=\"\" width=\"1342\" height=\"883\" class=\"size-full wp-image-2108\" srcset=\"https:\/\/krissmotors.com\/XJ6\/wp-content\/uploads\/END-CAP-@.png 1342w, https:\/\/krissmotors.com\/XJ6\/wp-content\/uploads\/END-CAP-@-330x217.png 330w, https:\/\/krissmotors.com\/XJ6\/wp-content\/uploads\/END-CAP-@-768x505.png 768w, https:\/\/krissmotors.com\/XJ6\/wp-content\/uploads\/END-CAP-@-1024x674.png 1024w\" sizes=\"auto, (max-width: 1342px) 100vw, 1342px\" \/><\/a><p id=\"caption-attachment-2108\" class=\"wp-caption-text\">Rocker panel end cap damage<\/p><\/div>\n<h4><span class=\"ez-toc-section\" id=\"Mitigation-3\"><\/span>Mitigation<span class=\"ez-toc-section-end\"><\/span><\/h4>\n<p>A small metal tip strip was welded in to provide structural support, then seam sealant and 3M rubberized undercoating completed the repair.<\/p>\n<div id=\"attachment_2118\" style=\"width: 719px\" class=\"wp-caption alignnone\"><a href=\"https:\/\/krissmotors.com\/XJ6\/wp-content\/uploads\/rocker-end.png\"><img loading=\"lazy\" decoding=\"async\" aria-describedby=\"caption-attachment-2118\" src=\"https:\/\/krissmotors.com\/XJ6\/wp-content\/uploads\/rocker-end.png\" alt=\"\" width=\"709\" height=\"787\" class=\"size-full wp-image-2118\" srcset=\"https:\/\/krissmotors.com\/XJ6\/wp-content\/uploads\/rocker-end.png 709w, https:\/\/krissmotors.com\/XJ6\/wp-content\/uploads\/rocker-end-297x330.png 297w\" sizes=\"auto, (max-width: 709px) 100vw, 709px\" \/><\/a><p id=\"caption-attachment-2118\" class=\"wp-caption-text\">Reinforced edges on rocker panel end piece<\/p><\/div>\n<h3><span class=\"ez-toc-section\" id=\"Toe_board\"><\/span>Toe board<span class=\"ez-toc-section-end\"><\/span><\/h3>\n<p>So named because of its location just in front of the driver &#8212; or passenger &#8212; toes (when one&#8217;s leg is fully extended towards the firewall), the toe board structurally secures the leading edge of the floor pan and also provides a reinforced jacking point.<\/p>\n<div id=\"attachment_1502\" style=\"width: 1286px\" class=\"wp-caption alignnone\"><a href=\"https:\/\/krissmotors.com\/XJ6\/wp-content\/uploads\/2017\/04\/toe-board.png\"><img loading=\"lazy\" decoding=\"async\" aria-describedby=\"caption-attachment-1502\" src=\"https:\/\/krissmotors.com\/XJ6\/wp-content\/uploads\/2017\/04\/toe-board.png\" alt=\"\" width=\"1276\" height=\"913\" class=\"size-full wp-image-1502\" srcset=\"https:\/\/krissmotors.com\/XJ6\/wp-content\/uploads\/2017\/04\/toe-board.png 1276w, https:\/\/krissmotors.com\/XJ6\/wp-content\/uploads\/2017\/04\/toe-board-330x236.png 330w, https:\/\/krissmotors.com\/XJ6\/wp-content\/uploads\/2017\/04\/toe-board-768x550.png 768w, https:\/\/krissmotors.com\/XJ6\/wp-content\/uploads\/2017\/04\/toe-board-1024x733.png 1024w\" sizes=\"auto, (max-width: 1276px) 100vw, 1276px\" \/><\/a><p id=\"caption-attachment-1502\" class=\"wp-caption-text\">Toe board underside with nipple-like jacking point (right) and partially blocked drain hole (left)<\/p><\/div>\n<div id=\"attachment_2105\" style=\"width: 927px\" class=\"wp-caption alignnone\"><a href=\"https:\/\/krissmotors.com\/XJ6\/wp-content\/uploads\/toe-board-front.png\"><img loading=\"lazy\" decoding=\"async\" aria-describedby=\"caption-attachment-2105\" src=\"https:\/\/krissmotors.com\/XJ6\/wp-content\/uploads\/toe-board-front.png\" alt=\"\" width=\"917\" height=\"512\" class=\"size-full wp-image-2105\" srcset=\"https:\/\/krissmotors.com\/XJ6\/wp-content\/uploads\/toe-board-front.png 917w, https:\/\/krissmotors.com\/XJ6\/wp-content\/uploads\/toe-board-front-330x184.png 330w, https:\/\/krissmotors.com\/XJ6\/wp-content\/uploads\/toe-board-front-768x429.png 768w\" sizes=\"auto, (max-width: 917px) 100vw, 917px\" \/><\/a><p id=\"caption-attachment-2105\" class=\"wp-caption-text\">Toe board front (trailing surface of wheel well) during removal<\/p><\/div>\n<div id=\"attachment_2106\" style=\"width: 910px\" class=\"wp-caption alignnone\"><a href=\"https:\/\/krissmotors.com\/XJ6\/wp-content\/uploads\/Screen-Shot-2017-07-28-at-8.52.58-AM.png\"><img loading=\"lazy\" decoding=\"async\" aria-describedby=\"caption-attachment-2106\" src=\"https:\/\/krissmotors.com\/XJ6\/wp-content\/uploads\/Screen-Shot-2017-07-28-at-8.52.58-AM.png\" alt=\"\" width=\"900\" height=\"421\" class=\"size-full wp-image-2106\" srcset=\"https:\/\/krissmotors.com\/XJ6\/wp-content\/uploads\/Screen-Shot-2017-07-28-at-8.52.58-AM.png 900w, https:\/\/krissmotors.com\/XJ6\/wp-content\/uploads\/Screen-Shot-2017-07-28-at-8.52.58-AM-330x154.png 330w, https:\/\/krissmotors.com\/XJ6\/wp-content\/uploads\/Screen-Shot-2017-07-28-at-8.52.58-AM-768x359.png 768w\" sizes=\"auto, (max-width: 900px) 100vw, 900px\" \/><\/a><p id=\"caption-attachment-2106\" class=\"wp-caption-text\">Removed damaged toe board versus new replacement<\/p><\/div>\n<h4><span class=\"ez-toc-section\" id=\"Mitigation-4\"><\/span>Mitigation<span class=\"ez-toc-section-end\"><\/span><\/h4>\n<div id=\"attachment_2110\" style=\"width: 610px\" class=\"wp-caption alignnone\"><a href=\"https:\/\/krissmotors.com\/XJ6\/wp-content\/uploads\/toe-board-installed.png\"><img loading=\"lazy\" decoding=\"async\" aria-describedby=\"caption-attachment-2110\" src=\"https:\/\/krissmotors.com\/XJ6\/wp-content\/uploads\/toe-board-installed-1024x783.png\" alt=\"\" width=\"600\" height=\"459\" class=\"size-large wp-image-2110\" srcset=\"https:\/\/krissmotors.com\/XJ6\/wp-content\/uploads\/toe-board-installed-1024x783.png 1024w, https:\/\/krissmotors.com\/XJ6\/wp-content\/uploads\/toe-board-installed-330x252.png 330w, https:\/\/krissmotors.com\/XJ6\/wp-content\/uploads\/toe-board-installed-768x587.png 768w, https:\/\/krissmotors.com\/XJ6\/wp-content\/uploads\/toe-board-installed.png 1174w\" sizes=\"auto, (max-width: 600px) 100vw, 600px\" \/><\/a><p id=\"caption-attachment-2110\" class=\"wp-caption-text\">Toe board riveted and sealed<\/p><\/div>\n<h3><span class=\"ez-toc-section\" id=\"Floor_pans\"><\/span>Floor pans<span class=\"ez-toc-section-end\"><\/span><\/h3>\n<div id=\"attachment_1505\" style=\"width: 340px\" class=\"wp-caption alignleft\"><a href=\"https:\/\/krissmotors.com\/XJ6\/wp-content\/uploads\/2017\/04\/toe-corner.png\"><img loading=\"lazy\" decoding=\"async\" aria-describedby=\"caption-attachment-1505\" src=\"https:\/\/krissmotors.com\/XJ6\/wp-content\/uploads\/2017\/04\/toe-corner-330x327.png\" alt=\"\" width=\"330\" height=\"327\" class=\"size-medium wp-image-1505\" srcset=\"https:\/\/krissmotors.com\/XJ6\/wp-content\/uploads\/2017\/04\/toe-corner-330x327.png 330w, https:\/\/krissmotors.com\/XJ6\/wp-content\/uploads\/2017\/04\/toe-corner-150x150.png 150w, https:\/\/krissmotors.com\/XJ6\/wp-content\/uploads\/2017\/04\/toe-corner-768x760.png 768w, https:\/\/krissmotors.com\/XJ6\/wp-content\/uploads\/2017\/04\/toe-corner.png 855w\" sizes=\"auto, (max-width: 330px) 100vw, 330px\" \/><\/a><p id=\"caption-attachment-1505\" class=\"wp-caption-text\">Inside corner where floor pan meets toe enclosure<\/p><\/div>\n<p>On wet days, moisture from the foot pedals puddles at the front of the floor pan and finds its way into the toe board enclosure. As debris fills the space and blocks the drain hole, rusting begins in earnest. This damages both the toe board as well as the edge of the floor pan. Fortunately, these parts are still available. <\/p>\n<p>There is metal damage along both right and left weld lines where the floor pans meet the toe box. Poor jacking technique (that is, lifting the car up without regard to the jacking points!) dimpled the front of both pans as well. <\/p>\n<h4><span class=\"ez-toc-section\" id=\"Mitigation-5\"><\/span>Mitigation<span class=\"ez-toc-section-end\"><\/span><\/h4>\n<p>To fix everything, both left and right pans and the driver&#8217;s toe board were cut out and new parts welded\\riveted in.<\/p>\n<p><a href=\"https:\/\/krissmotors.com\/XJ6\/wp-content\/uploads\/floor-pan-before-and-after.png\"><img loading=\"lazy\" decoding=\"async\" src=\"https:\/\/krissmotors.com\/XJ6\/wp-content\/uploads\/floor-pan-before-and-after.png\" alt=\"\" width=\"958\" height=\"687\" class=\"alignnone size-full wp-image-2147\" srcset=\"https:\/\/krissmotors.com\/XJ6\/wp-content\/uploads\/floor-pan-before-and-after.png 958w, https:\/\/krissmotors.com\/XJ6\/wp-content\/uploads\/floor-pan-before-and-after-330x237.png 330w, https:\/\/krissmotors.com\/XJ6\/wp-content\/uploads\/floor-pan-before-and-after-768x551.png 768w\" sizes=\"auto, (max-width: 958px) 100vw, 958px\" \/><\/a><\/p>\n<h3><span class=\"ez-toc-section\" id=\"Heater_core_corrosion\"><\/span>Heater core corrosion<span class=\"ez-toc-section-end\"><\/span><\/h3>\n<div id=\"attachment_1513\" style=\"width: 340px\" class=\"wp-caption alignleft\"><a href=\"https:\/\/krissmotors.com\/XJ6\/wp-content\/uploads\/2017\/04\/tunnel-damage.png\"><img loading=\"lazy\" decoding=\"async\" aria-describedby=\"caption-attachment-1513\" src=\"https:\/\/krissmotors.com\/XJ6\/wp-content\/uploads\/2017\/04\/tunnel-damage-330x259.png\" alt=\"\" width=\"330\" height=\"259\" class=\"size-medium wp-image-1513\" srcset=\"https:\/\/krissmotors.com\/XJ6\/wp-content\/uploads\/2017\/04\/tunnel-damage-330x259.png 330w, https:\/\/krissmotors.com\/XJ6\/wp-content\/uploads\/2017\/04\/tunnel-damage-768x603.png 768w, https:\/\/krissmotors.com\/XJ6\/wp-content\/uploads\/2017\/04\/tunnel-damage.png 870w\" sizes=\"auto, (max-width: 330px) 100vw, 330px\" \/><\/a><p id=\"caption-attachment-1513\" class=\"wp-caption-text\">Arrow indicates rust hole at tunnel top corner<\/p><\/div>\n<p>Jaguar tucked the heater core into a shelf just above the beginning of the transmission tunnel. Condensation dripped down the support leg and seeped into the carpet and jute backing where the moisture eventually eroded part of the tunnel sheet metal.  <\/p>\n<p>Damage is non-structural; the rust holes will be patched with riveted sheet metal for a watertight seal. (The new climate control system <em>will not<\/em> place the heater core in the same location.)<\/p>\n<h4><span class=\"ez-toc-section\" id=\"Mitigation-6\"><\/span>Mitigation<span class=\"ez-toc-section-end\"><\/span><\/h4>\n<p>The corner damage is small in area but a little tricky to cover adequately. A piece of 16 gauge metal was worked into the space and then riveted securely.<\/p>\n<div id=\"attachment_2153\" style=\"width: 756px\" class=\"wp-caption alignnone\"><a href=\"https:\/\/krissmotors.com\/XJ6\/wp-content\/uploads\/corner-patch.jpg\"><img loading=\"lazy\" decoding=\"async\" aria-describedby=\"caption-attachment-2153\" src=\"https:\/\/krissmotors.com\/XJ6\/wp-content\/uploads\/corner-patch.jpg\" alt=\"\" width=\"746\" height=\"900\" class=\"size-full wp-image-2153\" srcset=\"https:\/\/krissmotors.com\/XJ6\/wp-content\/uploads\/corner-patch.jpg 746w, https:\/\/krissmotors.com\/XJ6\/wp-content\/uploads\/corner-patch-274x330.jpg 274w\" sizes=\"auto, (max-width: 746px) 100vw, 746px\" \/><\/a><p id=\"caption-attachment-2153\" class=\"wp-caption-text\">Riveted corner patch covers heater core damage<\/p><\/div>\n<p>A larger patch was required on the passenger side just above the floor pan which was also caused by heater core moisture. Prior to final riveting, the sheet metal is held in place with cleco fasteners to adjust the fit.<\/p>\n<div id=\"attachment_2155\" style=\"width: 1210px\" class=\"wp-caption alignnone\"><a href=\"https:\/\/krissmotors.com\/XJ6\/wp-content\/uploads\/bottom-patch-cleco.png\"><img loading=\"lazy\" decoding=\"async\" aria-describedby=\"caption-attachment-2155\" src=\"https:\/\/krissmotors.com\/XJ6\/wp-content\/uploads\/bottom-patch-cleco.png\" alt=\"\" width=\"1200\" height=\"775\" class=\"size-full wp-image-2155\" srcset=\"https:\/\/krissmotors.com\/XJ6\/wp-content\/uploads\/bottom-patch-cleco.png 1200w, https:\/\/krissmotors.com\/XJ6\/wp-content\/uploads\/bottom-patch-cleco-330x213.png 330w, https:\/\/krissmotors.com\/XJ6\/wp-content\/uploads\/bottom-patch-cleco-768x496.png 768w, https:\/\/krissmotors.com\/XJ6\/wp-content\/uploads\/bottom-patch-cleco-1024x661.png 1024w\" sizes=\"auto, (max-width: 1200px) 100vw, 1200px\" \/><\/a><p id=\"caption-attachment-2155\" class=\"wp-caption-text\">Cleco fasteners hold bottom patch from the inside<\/p><\/div>\n<div id=\"attachment_2640\" style=\"width: 909px\" class=\"wp-caption alignnone\"><a href=\"https:\/\/krissmotors.com\/XJ6\/wp-content\/uploads\/heater-core-repair.png\"><img loading=\"lazy\" decoding=\"async\" aria-describedby=\"caption-attachment-2640\" src=\"https:\/\/krissmotors.com\/XJ6\/wp-content\/uploads\/heater-core-repair.png\" alt=\"\" width=\"899\" height=\"453\" class=\"size-full wp-image-2640\" srcset=\"https:\/\/krissmotors.com\/XJ6\/wp-content\/uploads\/heater-core-repair.png 899w, https:\/\/krissmotors.com\/XJ6\/wp-content\/uploads\/heater-core-repair-330x166.png 330w, https:\/\/krissmotors.com\/XJ6\/wp-content\/uploads\/heater-core-repair-768x387.png 768w\" sizes=\"auto, (max-width: 899px) 100vw, 899px\" \/><\/a><p id=\"caption-attachment-2640\" class=\"wp-caption-text\">Heater core and floor pan restoration viewed from engine bay<\/p><\/div>\n<h3><span class=\"ez-toc-section\" id=\"Front_trailing_stone_guards\"><\/span>Front trailing stone guards<span class=\"ez-toc-section-end\"><\/span><\/h3>\n<p>The XJ6 features bolt-on stone guards at the back of the front wheel wells that can easily be replaced if damaged or rusted. In our case, rust has eaten through the lower right side guard; both sides were replaced since the repair is easy with no need for welding.<\/p>\n<div id=\"attachment_1506\" style=\"width: 1296px\" class=\"wp-caption alignnone\"><a href=\"https:\/\/krissmotors.com\/XJ6\/wp-content\/uploads\/2017\/04\/guard-pocket.png\"><img loading=\"lazy\" decoding=\"async\" aria-describedby=\"caption-attachment-1506\" src=\"https:\/\/krissmotors.com\/XJ6\/wp-content\/uploads\/2017\/04\/guard-pocket.png\" alt=\"\" width=\"1286\" height=\"899\" class=\"size-full wp-image-1506\" srcset=\"https:\/\/krissmotors.com\/XJ6\/wp-content\/uploads\/2017\/04\/guard-pocket.png 1286w, https:\/\/krissmotors.com\/XJ6\/wp-content\/uploads\/2017\/04\/guard-pocket-330x231.png 330w, https:\/\/krissmotors.com\/XJ6\/wp-content\/uploads\/2017\/04\/guard-pocket-768x537.png 768w, https:\/\/krissmotors.com\/XJ6\/wp-content\/uploads\/2017\/04\/guard-pocket-1024x716.png 1024w\" sizes=\"auto, (max-width: 1286px) 100vw, 1286px\" \/><\/a><p id=\"caption-attachment-1506\" class=\"wp-caption-text\">Stone guard covers a pocket area (note vent hole) that survived in good condition<\/p><\/div>\n<div id=\"attachment_2747\" style=\"width: 1010px\" class=\"wp-caption alignnone\"><a href=\"https:\/\/krissmotors.com\/XJ6\/wp-content\/uploads\/IMG_1482.png\"><img loading=\"lazy\" decoding=\"async\" aria-describedby=\"caption-attachment-2747\" src=\"https:\/\/krissmotors.com\/XJ6\/wp-content\/uploads\/IMG_1482.png\" alt=\"\" width=\"1000\" height=\"889\" class=\"size-full wp-image-2747\" srcset=\"https:\/\/krissmotors.com\/XJ6\/wp-content\/uploads\/IMG_1482.png 1000w, https:\/\/krissmotors.com\/XJ6\/wp-content\/uploads\/IMG_1482-330x293.png 330w, https:\/\/krissmotors.com\/XJ6\/wp-content\/uploads\/IMG_1482-768x683.png 768w\" sizes=\"auto, (max-width: 1000px) 100vw, 1000px\" \/><\/a><p id=\"caption-attachment-2747\" class=\"wp-caption-text\">New bolt-on stone guard<\/p><\/div>\n","protected":false},"excerpt":{"rendered":"<p>Frame In general our 1972 XJ6 body and chassis survived in excellent condition. The paint isn&#8217;t original, but the repaint color match is perfect. There are a few surface dings and scratches, but nothing that requires any metal work on the body itself. However, the chassis has several vulnerable points&#46;&#46;&#46;<\/p>\n","protected":false},"author":1,"featured_media":1505,"comment_status":"open","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"_acf_changed":false,"footnotes":""},"categories":[21],"tags":[19],"class_list":["post-1497","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-body-preparation","tag-fabrication"],"acf":[],"_links":{"self":[{"href":"https:\/\/krissmotors.com\/XJ6\/wp-json\/wp\/v2\/posts\/1497","targetHints":{"allow":["GET"]}}],"collection":[{"href":"https:\/\/krissmotors.com\/XJ6\/wp-json\/wp\/v2\/posts"}],"about":[{"href":"https:\/\/krissmotors.com\/XJ6\/wp-json\/wp\/v2\/types\/post"}],"author":[{"embeddable":true,"href":"https:\/\/krissmotors.com\/XJ6\/wp-json\/wp\/v2\/users\/1"}],"replies":[{"embeddable":true,"href":"https:\/\/krissmotors.com\/XJ6\/wp-json\/wp\/v2\/comments?post=1497"}],"version-history":[{"count":56,"href":"https:\/\/krissmotors.com\/XJ6\/wp-json\/wp\/v2\/posts\/1497\/revisions"}],"predecessor-version":[{"id":2749,"href":"https:\/\/krissmotors.com\/XJ6\/wp-json\/wp\/v2\/posts\/1497\/revisions\/2749"}],"wp:featuredmedia":[{"embeddable":true,"href":"https:\/\/krissmotors.com\/XJ6\/wp-json\/wp\/v2\/media\/1505"}],"wp:attachment":[{"href":"https:\/\/krissmotors.com\/XJ6\/wp-json\/wp\/v2\/media?parent=1497"}],"wp:term":[{"taxonomy":"category","embeddable":true,"href":"https:\/\/krissmotors.com\/XJ6\/wp-json\/wp\/v2\/categories?post=1497"},{"taxonomy":"post_tag","embeddable":true,"href":"https:\/\/krissmotors.com\/XJ6\/wp-json\/wp\/v2\/tags?post=1497"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}