First I removed all material below the 70% (original material left) and then remade all missing parts. Sprayed again everything in zinc paint and welded everything back to there original positions.

Left Side                                                            Right Side

In the direct neighborhood of my home there is a jaguar garage situated and I could borough one from them. It was a cover from a XK150 but they should be interchangeable and could be used as an example.

• The valance assembly has several holes of 1″”  drilled for some unknown reason.
• Headlight pod has extensive rust in the under side of the headlight mounting area.
• The lower edge of the front side has a small hole due to rust (about 2″ by 1/4″)
• The steady bracket which mount to the battery box has some rust
• Dents in the area around the flashing light (due to badly repair after a collision in the past)

Cleaning the inside

The inside of the wings are protected with a very tick layer of tar which protected the inside from rust.
From the photo it is clearly visible that it did his you very well. The right side, the part behind the mud shield, which was not protected is much more affected by rust.

After the layer of tar was removed with a small torch and a putty knife the undamaged metal became visible.

When the whole surface was cleaned with a poly-carbide steel brush the front wing looks like new again. All difficult to reach area’s are now sandblasted so the inside is now ready to receive the first layer of epoxy primer.

 Headlight pod

Due to long lasting condensation inside the headlight pod the lower part has been damaged by extensive rust. First the lead, used to smooth up the connection between headlight pod and front wing, is removed. Now all by rust affected material is removed and the holes in the front wing are welded. Now we know how much material is missing we can start with producing the new pieces.

The new pieces are fitted for the last time and welded unto the headlight pod. The last step is reapply the lead to smooth out connection between the wing and headlight pod.

When I was investigating the headlight pod from the right side front wing (which is not rusted at all) i found a small hole in the lowest part. My first impression was that there was a small hole due to rust but after looking in more detail to the inside area it looks like a small hole to drain water. I will make such a hole in the left headlight pod as well.

The valance assembly

The holes in the left front valance, which are certainly not original, needs to be removed.  In total 9 holes where drilled. With this amount of holes it is better to just remove the hole affected area as one piece and remove it for a new piece.

Painting

The inside inclusive the valance will be painted in the following order:

• Epoxy primer
• Body schutz (Protective coating helps protect from corrosion and chips)
• The inside will be painted satin gloss
• The following parts are painted in Pearl grey
  • Valance assembly (both sides)
  • Headlamp light unit container (inside)
  • Side lamps casing (inside)

The left rear wing has two attention areas;

• The lower edge at the door side
• The upper part also at the door side

The repair areas marked with grey paint

Cleaning

Now that the rear wing has been repaired the thin layer of rust can be easily removed with a wire brush and sand paper.

Painting

Now that the inside is nicely shining again the following activities can take place;

• Apply a fresh layer of Epoxy primer.
• Make sure all seals are seamed. (3M Heavy Drip-Chek Sealer)
• Apply a protective layer to prevent chipping. (3M Textured Anti-chip Coating)
• Last but not least a layer of satin black paint to make it easier to clean the inside.

After the new panel was remounted the overlapping areas on both sides should be filled with lead. I don’t want to use putty because originally they used lead as well. Lead soldering looks easy but it is much more difficult as it looks. The advantage is that the lead can be reused time after time. So with a lot of patient I succeeded at the end. With just a thin layer of zinc spray everything looks like new again.

• Dents in the area around the flashing light (due to badly repair after a collision in the past)
• The lower edge of the wing nearby the right door has a lot of rust. This together with the lower part of the door hinge plate needs to be repaired with new pieces of metal.

Cleaning the inside

After I followed the same procedure as with the left front wing this wing also looks like new again.

The lower wing edge

The state of the lower front wing edge partly rusted away and replacing this whole area is inevitably.

Cut out of the rusted part

Painting

Now that the right front wing has been cleaned and repaired it can be painted. We start with Epoxy primer followed by a protective layer to prevent chipping and as last a layer of black paint. This last layer of paint will make it easier to clean the inside. The parts visible from the engine compartment will be painted in the car color.

The right rear wing has three attention areas;

• The lower edge at the door side
• The upper part also at the door side
• the lower edge on the backside of the car

The repair areas marked with grey paint

Cleaning

Now that the rear wing has been repaired the thin layer of rust can be easily removed with a wire brush and some sand paper.

Painting

Now that the inside is nicely shining again the following activities can take place;

• Apply a fresh layer of Epoxy primer.
• Make sure all seals are seamed. (3M Heavy Drip-Chek Sealer)
• Apply a protective layer to prevent chipping. (3M Textured Anti-chip Coating)
• Last but not least a layer of satin black paint to make it easier to clean the inside.

Shutface Pilar Left

Inside Shutface Pilar Right

Outside Shutface Pilar Right

Remark:
Always keep the body bolted on to the chassis during welding jobs to prevent the body will warp or twist