1952 Jaguar XK120 restoration

I wonder whether that would work on aluminium. I’ve had problems with cracking of the weld if it cools too fast.

This is a work of art in the level of detail and attention. I love following the progress!

Nice modification to make things a bit more practical.
I wonder if some motorbike filter would work? They come in various shapes usually with a hole in the middle already, and usually preoiled. Generally about the right thickness too.
They used to sell them at Supercheap but not sure if that's the case anymore.

Agreed, a bike filter would work. Finding the dimensions is difficult though.

So I ordered a 400x300 sheet of dual layer air filter foam. Won’t need nearly that much but I couldn’t find any smaller.


Lots of little jobs on the menu at the moment.
Wiring is getting close to complete. Waiting on some screws to fit the p clips I made a while back, then I can finalise the position of the harness.

These cars originally had two 6 volt batteries in series. I decided to go with two small 12 volt in parallel. Should have plenty of cranking power. Made a pair of clamps from 5mm ally to hold them in place.




Waiting on some battery terminal clamps so I can make some leads.



Needed some long dome nuts for the rear bumpers. Got some joiner nuts and removed the zinc plating.








Then brazed one end closed.










Spun them in the lathe while shaping the end with a flap disk in the angle grinder. Then sanded with 320, then 600 grit.










After polishing.










And plated.









Also got the spare tyre area finished.












That’s all for now. Comments, suggestions and queries welcome.
Cheers.

Old news now, but I'm glad that your thumb is working OK. I think we have all picked up wounds in the course of our interests! But stunning work, as ever, on your car.

Going to be a real beauty once you've put it back together.

Just the thing for sunny days on back roads.

Thanks Duggy, 75. Much appreciated.

Air filters are done.
Sheet of dual layer foam arrived. Cut a 50mm strip and reassembled. Piece of cake. Would have preferred that the outer layer of foam was black, but you can’t have everything…







The crash or D rolls are the next project. These look like they’re going to be challenging.
The red line shows them on this pic from the web.










They’re called D rolls because the rubber that they take their name from has a D section.
They go right around the cabin, four pieces in total. All similar construction but all different shapes.
Quite complicated. Also right in view, so important to get them right.

That’s all for now. Comments etc.
Cheers

Air filters match the car colour at least

Thanks for the suggestion Duggy, but I’ve got the original d roll rubber. The rest is just leather, glue and bits and pieces.

 I didn’t really consider that the colour of the foam would be a thing, when I ordered it. Lucky it wasn’t a colour that stood out but didn’t work.


Boot trim is trimmed. Pleased with how this turned out.









Now for the d rolls.
Made up of a few bits, but fairly complicated to put together.
This is a drawing I did when I removed them, so I’d know how they were done. This wasn’t actually the door, it was the scuttle. The leather was just wrapped around and glued, not stapled.











Also needed is something attached to the body to staple the leather to.
On the doors it’s a piece of 3mm mdf screwed in place.











The tonneau has these pieces. Were originally bare metal, now painted with black gloss. Note semi healed thumb!









Then a piece of ply is screwed to them, to which the leather can be stapled.











The leather will be stapled to pieces of 18mm mdf fixed behind the edges of the scuttle and the tonneau. Here a length is clamped in place to mark the shape.












One of the smaller side pieces ready to fit. These bits are fixed with countersunk self tappers.









There’s  a strip of (usually ) ply screwed to the top of the doors ( or the tonneau, or the scuttle)
I’m using  my favourite sign board instead. It’s easy to work and totally weatherproof.
A fair bit of adjustment to get it to fit nicely. Should have used countersunk rivets on the door construction, but grinding small recesses allowed the strip to sit flat. Held on with countersunk screws.












Next sew up a piece of piping.
Then a piece of leather and it are glued to the underside of the strip













And the lot screwed in place.








Two doors, scuttle and tonneau - plenty to do.


That’s all for now. Etc.
Cheers