Part 7 - For The Love of Rust

You may recall that the aborted trip to Cornwall turned out to have a rusty lining: When the car came off the transporter, holes had magically appeared in both sills where filler from previous bodged repairs had shaken free, leaving fresh air where metal once kept the car together. With my eldest son suitably bribed (with an entry in the XJS at an Autotest) and a dear friend's offer of a dry Essex barn to work in, we started cutting away the rusty mess. My hope was that the front and rear sill repair sections I had ordered from xjspanelshop.co.uk would be sufficient and that we would not need the very expensive genuine sills. Let the welding begin It had been a job that I had been putting off for months...but now we had made the first cut, there was no going back. More and more rusty metal dropped onto the barn's floor until we were left with the ugly truth! Fortunately the front end of the inner sills just needed a patch to repair before the replaceme...