How do you fit lower rocker panel on x type jaguar?

Answer 1

I take it you mean the section of steel body work under the doors also known as sills in the UK.

These are very prone to rust in earlier models, and is not an easy job.

a) disconnect the EMU - under the bonnet left hand side at the back held on by one anti-tamper screw

b) disconnect the two connections to the alternator front of engine bay under the air filter box which will need to be removed.

c) as far as I know there are no pattern parts for the repair in the UK only jaguar are available at £360 EACH however sheet metal shops can supply parts from your design (if you like try Hutcheon Services Aberdeen, Scot)

d) remove the outer plastic cover, plastic screws underneath and clips at the side, remove inner plastic wings front and rear, remove lower front wing and prise away from body for access

d) the sill is made up of four sections

• Outer sill which you can see when you remove the plastic sill

Cut approximately 10mm down from the 90deg fold in the vertical section and grind out spot welds on the lower body flange, Note; at the rear leave in the expanded section (80MM) and cut under the sill 20mm

A bottle jack and a strip of wood may be required to push in the panel at the lower sill when re fitting - work from back to front fitting a temporary fixing screw / poprivet every 200mm

Note there are also plug welds underneath to the inner / outer sill

• Inner / outer sill

Cut approximately 20mm down from the outer sill cut, right up to the front wheel arch (repair for re-use)

• Inner / inner sill

There is a good chance that the lower section is rusted out if so cut away just under the section openings - repair strip required

• Inner / outer sill

Check that the lower flange is re usable and start to re-weld in all the components

The outer / outer sill may require a 2 part repair patch under the front wheel arch

I found that in-conjunction with a 1mm thick cutting disk an electrical hand held chop saw with a metal cutting blade give a good straight cut (Orange black & Decker about £40)

The front door may require removing, however it can be temporarily held up by an engine hoist to save disconnecting the electrics.

Well not for the feint hearted, the moral of the story, buyer beware and get the waxoil in to the sills / rocker panels ASAP

Regards

Frank