The problem with rust at the bottom of the front wing (fender) on the XJ
is more fundamental - it is a dire design problem in the construction in
this region. The ASCII art below shows the arrangement in vertical
cross section. The bottom of the wing has a tight U-shaped fold, to
which is spot welded a bracket with holes to accommodate the two
downward-facing securing bolts behind the splash panel. The drain holes
are in this welded-on bracket, and are higher than the bottom of the
fold in the metal at the bottom of the wing. So water/grit/mud/salt
just accumulates in there even if the drain holes are free from
obstruction. I know from experience that it takes nine years in the UK
for a wing to rust through there.
The only way to stop this is to seal the bottom of the wing with
automotive joint sealer when it is new or nearly new. I replaced one of
mine (for exactly this reason - rust bubbles below the badge) with a
good replacement one, but I carefully pried open the U, and had a local
guy grit blast the rust out down to clean metal. I then primed it,
filled it with sealant and then crimped the U closed again. The wing
was then sprayed the correct colour. That sucker won’t rust!
Craig
-!
Badge ! ! Inside splash panel
-!
!
Outside ! ___Securing bolt
! ! !
! ! --------
! ! Drain
! !
!-! Fold in metal at bottom of wing (fender)> The rust around the Jaguar badge on the front fender can be
easily repaired;
access is by removal of the splash panel in the front fender;
the rust is
cause by a failure in the sealing of the at panel, allowing a build up
of mud; this mud is then kept damp by the drains from the
sunroof which
exit into this cavity; if the outlet holes provided are also
clogged by
mud (salty mud in many cases) then corrosion results.Gregory