[x-type] Rusting sills

The sills on my 2002 X type have rusted through from the inside out
in several places under the plastic side skirts. Has this happend
to anyone else?
Is there a repair section available to repair the sills?

Thanks
Liam–
Liam
Newcastle upon Tyne, United Kingdom
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In reply to a message from Liam sent Sat 9 Oct 2010:

This will make you sick

http://jaguarforums.com/forum/showthread.php?t=35123--
Anthony Hladun
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In reply to a message from Anthony Hladun sent Sun 10 Oct 2010:

O Bu@@er, that doesn’t look good.
Could this be the end of my X type? Looks like it’ll cost more than
the car is worth to repair.–
Liam
Cleveland, United Kingdom
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In reply to a message from Liam sent Sat 9 Oct 2010:

Hi,

I have a 03 plate and I examined the sills about a month ago after
reading about this on another forum. As far as I can tell the front
ends are fine except the paint is a bit pitted. Also the A post
seem to be fine. At the rear ends I found some paint adjacent to
the jacking points flaking off. Although rusty there ( a patch
about 1.5 inches by 1 inch either side) it seems to be solid so I
am hoping this is only surface rust caused by placing a jack there.
Anyway I have cleaned them up and painted the entire length with
underseal and squirted liberal amounts of waxoyl in them via the
drain holes.
I agree that the finish and protection of the sills is poor. I was
going to buy a newer diesel model next year but now I am not sure.
It�s a pity because it is such a reliable nice car in most respects.–
The original message included these comments:

in several places under the plastic side skirts. Has this happend
to anyone else?


oldy52
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In reply to a message from oldy52 sent Sat 16 Oct 2010:

Have taken my car to several body shops all quoting around �1300 to
repair both sills. Most hadn’t come across this problem before but
I’m getting a bloke who has done loads over the past year, (he is
just opposite my local jag specialist). Apparently there are no
drain holes at the front end of the sills, I think he said that
there are holes there but they get covered when the sill is fitted!
As he does his repairs he modifies the sill so water can drain out.
Think that around 2004 Jaguar realised there was a problem and
modified the sills.
Trouble is once the outer sill has rusted through the inner sill
will be just as bad but you can’t see that until you have cut the
outer sills off.–
Liam
Cleveland, United Kingdom
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In reply to a message from Liam sent Tue 19 Oct 2010:

Are any of these panels providing significant structural integrity
to the unibody?–
Robert Allen
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In reply to a message from rea1980 sent Tue 19 Oct 2010:

More than significant, they are the primary structure.–
Anthony Hladun
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In reply to a message from Anthony Hladun sent Tue 19 Oct 2010:

Remind me to inspect my car. If this is the primary structure in
the unibody, rust here could officially be classified as a very bad
thing.–
The original message included these comments:

More than significant, they are the primary structure.


Robert Allen
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In reply to a message from rea1980 sent Tue 19 Oct 2010:

Have just got my car back from having sills repaired took 4 and a
half days and cost �1400. He showed me some photos he took, was
surprising how much rot there was, wasn’t much left to be cut out!

From the outside all that you could see a couple of areas of paint
bubbling and a couple of small holes in sill underneath. MOT next
week, at least it’ll not fail because of rusty sills.–
Liam
Cleveland, United Kingdom
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In reply to a message from Liam sent Sat 20 Nov 2010:

Had similar with my 2001 3.0l SE, decided to off-load it as
px for my wifes new MX5, keep debating whether to get
another or wait until I can get an XF.

sort of a hard decision!–
The original message included these comments:

Have just got my car back from having sills repaired took 4 and a
surprising how much rot there was, wasn’t much left to be cut out!


3.0 SE (2001)
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Replacing the sill on an X type is relatively simple, but you do need to be able to weld. I had never welded before, but I decided to replace the sills myself. Welding machine £80 from Aldi, Self dimming welding helmet £20 from Aldi, new sills that were formed to fit my car £80 for the pair, welding rods £10 from ebay, also purchased a couple of flapper grinding discs £10 .

Watched a few videos on Utube, then set about welding a couple of scrap pieces of metal, took five attempts to weld, then suddenly I got the hang of it, cut out all the rotted metal, then fitted the new sills, I used scissor jacks to position each sill, then I drilled a few holes and put screws in along the top of the new sill and into the old sill then started welding. I had before used my angle grinder with the flapper discs to clean up the old sills that I had left.

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I’m buying an X-Type estate for UK family visits and was sad to see that a few 2007-2009 cars still showed rust repairs in their MOT history. Well past their warranty of course, but if they modified the design it still wasn’t a full cure.

But where can you get a nicer 50 mpg luxury estate with all the toys and no pointless expenses like tyre pressure monitor MOT fails?

The sills £70 the pair for precision cut sills on ebay, get yourself a stick welder £90 from Lidl or Aldi, some welding rods £20, you also need an angle grinder and some flapper disc. I watched a Utube video to learn how to weld. It’s an easy job to renew the sills on a Jaguar X Type, I had quotes of well over £1000 to replace mine, but I did it myself for £100, I managed to borrow a welding machine.

Liam!
You can always move to sunny New Mexico and you will not
have any problems with RUST.
Humidity here is usually 15 %

                                                                  Walter
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