Jaguar World Monthly Forum - Seatbelt & Footwell Rust repairs 94 V12

540itouring

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Seatbelt & Footwell Rust repairs 94 V12
30.10.2011 at 21:46:52

Hi , i am new to this forum but well known on most others and would like to show you what i am working on and other projects will follow. I have found rust by seatbelt mounting plate on floor and in footwell above drivers pedels. i have removed the plates and cut the rust away almost ready to weld new plates in and go onto rust prevention and sealing. This was only found after reading another owners letter in JWM last month as i had not seen any rust before. I plan to mig weld this with a BUTT weld once i get my new welder and have a good practice first.

http://tinyurl.com/6awnfpx

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« Last Edit: 31.10.2011 at 21:36:18 by 540itouring »

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mitchman Full Member Offline Posts: 211 Watford Gender:	Re: Seatbelt & Footwell Rust repairs 94 V12 Reply #1 - 10.11.2011 at 19:40:19 Some good pics there 540i - all XJSs seem to need this doing at some stage.
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540itouring I've just arrived Offline Posts: 26 Croydon Surrey Gender:	Re: Seatbelt & Footwell Rust repairs 94 V12 Reply #2 - 10.11.2011 at 19:55:38 Thank you for that. My new ESAB C200i welder will be delivered next week so looking forward to using that new toy. mitchman wrote on 10.11.2011 at 19:40:19: Some good pics there 540i - all XJSs seem to need this doing at some stage.
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540itouring

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Re: Seatbelt & Footwell Rust repairs 94 V12
Reply #3 - 02.02.2012 at 20:36:34

I now have my new welder and have made the first plate to fit and now plan to seam weld these plates on the inside of the floor. I will then treat the metal with a cleaner and coat them with por15 . The edges of the plates will also be sealled with a car body sealant to prevent water etc. The picture link has been updated with a few extra pics to show the first plate ready. I will update more when i make more plates and start welding. The weather is too cold in my garage to work so awaiting a temp increase !

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Anjum

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Re: Seatbelt & Footwell Rust repairs 94 V12
Reply #4 - 06.02.2012 at 11:59:38

Good work.
POR-15 is great but is very particular as to preparation. You need to follow the instructions precisely. I.e clean thoughly. Prepare new metal with Metal Ready and wash off with water (not solvent). Dry thoughly, use a hair dryer or heat gun then apply the POR-15 in two layers. I read somewhere that the siver is best for rust prevention.
I only say the above because some people have some bad experiences with the paint peeling away (partuculrily on non-rusty metal, and from what I can see it's probably because they didn't prepare it properly.

Is your car Flamenco Red as well? beutiful colour, even if I say so myself!

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540itouring

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Re: Seatbelt & Footwell Rust repairs 94 V12
Reply #5 - 23.03.2012 at 21:07:59

Yes my car is Flamenco Red and looks great when polished up. I have just got my welding gas bottle and regulator so will start my floor welding very soon . The gas i got is a mis of Argon / C02/and 2% O2 and this is ment for thin metal so perfect for the fllor repair. I have also changed the MIG wire from 0.8mm to the thinner 0.6mm to avoid blowing holes in the floor. I will update with pics when i do the first plate welding.

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Anjum Junior Member Offline Posts: 81 N London Gender:	Re: Seatbelt & Footwell Rust repairs 94 V12 Reply #6 - 27.03.2012 at 13:58:03 Where did you get your gas, and what size. I've just finished my BOC bottle and it's difficult getting it refilled at a reasonable price. Luckily I've finished all the welding but a source which doesn't involve a rental would be useful.
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almcl

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Re: Seatbelt & Footwell Rust repairs 94 V12
Reply #7 - 27.03.2012 at 18:17:06

Anjum wrote on 27.03.2012 at 13:58:03:

...BOC bottle and it's difficult getting it refilled at a reasonable price.

Ain't that the truth!

When I started welding (Oxy) £30 bought a five year rental and the cylinders cost a few quid to refill.

Now it's an astronomical amount for a couple of years and a cylinder costs as much as a tankful of petrol.

How come there's no competition? One firm seems to have a complete monoploy.

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'05 X 350 TDVi - his
'05 X type Est 2.0 D - hers
'93 4.0 XJS- theirs

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Brian

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Re: Seatbelt & Footwell Rust repairs 94 V12
Reply #8 - 27.03.2012 at 18:33:56

Having to rent bottles for my work, I just accept the cost.....but most of the 'home' welders I know have a deal with their local landlord and use 'pub' gas. Dosn't have the 2% argon, but plenty good enough for the average sill or floor repair, most people will not get a text book weld anyway. Air Products do a bottle that is 2/3 the size of BOC, but contains the same amount of gas, also has a built in reg and gauge plus quick plug in connector, think its called an' integrer ' or something like that, much easier to manhandle.
Brian

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1993 3.2 XJ40 & 1997 3.2 X300 executive

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540itouring

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Re: Seatbelt & Footwell Rust repairs 94 V12
Reply #9 - 28.03.2012 at 20:59:18

I ordered my bottle on the phone from Adams Gas . I have no afilliation with them but were easy to order from . the bottle was sent by a courier and total cost was £103 inc del. The cost is £36 for 9 Ltrs @137bar. inc vat. Dep of £55 + £12 del . £55 refundable when i no longer need a bottle .

This is my first bottle and must be much cheaper than throw away bottles that last a short time. I think i could have got the gas for £30 + the same extra charges from another online supplier but no local dealers to me so have to pay the extra courier charge. I have a regulator and flow meter which looks easy to set up flow rate and think it will last approx 140 mins .

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540itouring

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Re: Seatbelt & Footwell Rust repairs 94 V12
Reply #10 - 10.04.2012 at 00:13:26

Just to let you know in have started the welding and was ok apart from the galvernising . I will grind more off for the next patches and have now discovered that the metal by the passenger seat mounting is slightly rusted and showing three pin holes so will now cut that out. I have groung the patch and welding down and is very flat so do not thing you will see them once painted and undersealed etc. more pics to follow but please let me know what you think . So when i cut the next hole i will be left with three more holes to patch before i start to paint and seal up.

check the link in my other posts as its the same

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540itouring

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Re: Seatbelt & Footwell Rust repairs 94 V12
Reply #11 - 15.04.2012 at 22:52:14

I am still working on my floor rust and is taking a while as i
have problems with the galvanising on the floor but think i must
not have removed all so the next time i will sand it lightly
first . I am pleased with this so far as all seams very strong and
will be almost lost once finished with por 15 etc . This is a link
of my work so you can see what i have done so far . Please let me
know what you think. I still have a little grinding and some holes
to drill for the spotwelds and thats why some parts of the holes
are not welded. This is where the holes were in the old floor so
used then as markers

http://tinyurl.com/c9zdtw9

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almcl

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Re: Seatbelt & Footwell Rust repairs 94 V12
Reply #12 - 16.04.2012 at 06:59:40

Looks like some good work there.

One comment (and this is not a criticism of anything specific) is don't be shy about cutting out a little bit more metal.

Sometimes, I've found that going to straight edge and getting back to absolutely untouched metal makes for an easier and possibly more durable repair. Particularly if, like me, you have a talent for burning through things...

Off down to the gagarge now to cut some more rust from my Daimler's wheel arch.

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'05 X 350 TDVi - his
'05 X type Est 2.0 D - hers
'93 4.0 XJS- theirs

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XJ40S

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Re: Seatbelt & Footwell Rust repairs 94 V12
Reply #13 - 18.04.2012 at 12:29:25

Methylene chloride is good for cleaning up the area to reveal the extent of rust. This followed by steel wool or abrasive tape avoid thinning the metal (which makes welding harder). Cut back to as sound metal as possible.
Putting a lump of copper or aluminium on the back side acts as a heat sink / chill and and prevents burning through and oxidation on the reverse side. Copper is best.
Cheers

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