1993 XJS CONVERTIBLE 4.0 LITRE

BLASTING INNER EDGES OF WHEEL ARCH LIP (14/05/2026)

THE BLASTING FOCUSSED MAINLY ON FLOOR SECTIONS , ESPECIALLY AROUND 

SEAT BELT AND JACKING MOUNTS, BUT ALSO CONCENTRATED ON THE WHEEL ARCHES.

OUR BLASTER WAS ABLE TO CONTAIN THE BLAST MEDIA TO FOCUS ON MOSTLY THE

INNER EDGES. THE RUST CLEANED OF THESE AREAS VERY NICELY, AND NO HOLES 

WERE FOUND. 

JUNE 17TH 2026 (30/11/-0001)

QUITE A FEW UPDATES SINCE THE LAST REPORT. THE FUEL LINES WERE BARE

METALLED WHERE ACCESSIBLE AND PAINTED. ALL WELDING NOW COMPLETE.

NEW SECTIONS SEAM SEALED AND PAINTED. WILL BE WAXOYLED ONCE OTHER

WORKS COMPLETE. IN DISCUSSION WITH CUSTOMER ABOUT THE POSSIBILTY

OF FITTING AN ELECTRIC HANDBRAKE - QUITE A COMPLEX TASK . THE REPAIRED

SILL AREA NOW FILLED , AND NEW SWAGE LINES CUT BACK IN. CAR NOW NEEDS

EITHER PARTIAL OR COMPLETE RESPRAY - TBA. SPRING CUPS VERY RUSTY - NOW

CLEANED UP AND REPAINTED. SKI SLOPE / UPPER TRANS TUNNEL REMOVED - TO

ACCESS GEARBOX REMOTE RUBBERS - THESE WERE QUITE PERISHED, AND SEVERAL

SHIMS MISSING. CHANGED GEARBOX OIL. NEW CLUTCH MASTER CYLINDER FITTED. 

NEW IDENTICAL CLUTCH SLAVE CYLINDERS NO LONGER AVAILABLE - SO REPLACED

WITH A SIMILAR ITEM THAT NEEDED A CHANGE TO METRIC PIPEWORK AT THE SAME

TIME. FIT NEW EXPANSION CAP. REMOVE AND REPLACE NEW FRONT AND REAR SHOCKS.

REPLACE FUEL FILTER. FRONT BRAKE CALIPERS HAD NEW LOCKWIRE FITTED. 

OUR CUSTOMER MENTIONED THAT THE GLOVE BOX FILLED WITH RAIN WATER DURING

BAD WEATHER ! THE SCUTTLE SEAL WAS MISSING - HAVE REPAIRED THIS. WILL TEST

WITH HOAE TO ESTABLISH - IF THE CAR  STILL LEAKS - WHETER THE FRONT SCREEN 

NEEDS TO BE REMOVED AND FURTHER SCUTTLE REPAIR WORK CARRIED OUT.  DIFF OIL

CHANGED.   

BUMP STOPS (30/11/-0001)

AND FRONT DROP LINKS NOW BEING FITTED.

ROAD TEST LATE JUNE 2026 (30/11/-0001)

WE WANTED TO CARRY OUT A SHORT ROAD TEST.  BUT QUITE A FEW MORE JOBS NEEDED TO

BE CARRIED OUT. 

NEW FRONT SPRINGS , TO COMPLETE NOW A FULL FRONT AND REAR SUSPENSION CHANGE. BLEED BRAKES AND CLUTCH, AND UPGRADE FLUID TO BREMBO DOT 5.1 - MUCH HIGHER BOILING POINT. NEW UJ'S IN

REAR DRIVESHAFTS, NEW HUB BEARINGS FITTED, GEARBOX OIL UPGRADED TO REDLINE MT75 -

A VERY HIGH QUALITY PRODUCT.  RUST REPAIRS ALL SEAM SEALED AND PAINTED. WILL BE WAXOYLED, THEN LANOGUARDED FOR ULTIMATE PROTECTION.

, NEW ABS SENSOR, NEW DISTRIBUTOR CAP AND ROTOR ARM. FUEL LINES REPAINTED.

FRONT BRAKES RE LOCK WIRED. NEW FUEL FILTER. GOING TO FIT A FULLY ELECTRIC HANDBRAKE

SYSTEM USING TOP NOTCH WILWOOD CALIPERS AND VENTED RER DISCS - AN INTERESTING AND

EXCITING UPGRADE. THE CAR DROVE WELL ON ITS TEST. WE WANT TO GO FOR A LONGER TEST

ONCE THE ARCHES ETC PAINTED, BUT GEAR CHANGE MUCH SMOOTHER, AND HANDLING MUCH 

MORE COMPOSED.  

PASSENGER FLOOR SEAT ECU COVER HAD A ROTTED FRONT EDGE. COULDNT FIND A GOOD USED PANEL

ONLINE - THIS IS A COMMON ISSUE, SO FABRICATED A NEW LEADING EDGE TO REPAIR THE OLD ONE. 

JUNE 2026 (30/11/-0001)

WELDING NEAR COMPLETION. FOUND SOME MORE AREAS IN SILL ENDS, FLOOR

EDGES AND REAR CHASSIS AREAS ETC. NOW HAVE SHOCKS FITTED, AND BOTH

HUBS COMPLETELY REBUILT WITH NEW BEARINGS. RADIUS ARMS HAVE BOTH

BEEN REFURBISHED AND NEW BUSHES FITTED. 

FLOORS, SILLS, RADIUS ARMS, DRIVESHARFTS (30/11/-0001)

RUST IN FLOORS DRAWING TO A CLOSE, BUT THEN FOUND MORE IN SILL

ENDS, PLUS N/S REAR CHASSIS LEG, AND UNDER RADIUS ARMS. RADIUS

ARMS THEMSELVES REMOVED TO BE DE-RUSTED, AND TO HAVE NEW 

BUSHES PRESSED IN. THE REAR HUB BEARINGS ARE TO BE REPLACED, 

AND DRIVE-SHAFTS STRIPPED, RUST REMOVED, AND NEW UJ'S THEN A

FINAL REPAINT. 

MORE WELDING BELOW, CLEAN / REPLACE FUEL PIPES (30/11/-0001)

THE RUST IN THE FLOOR PANS BEING REMOVED, CUTTING RECTANGULAR SECTIONS

OUT AND DUPLICATING PROFILES FROM SHEET STEEL, THEN SEAM WELDING IN PLACE

AND FOLLOWING UP WITH SEAM SEALER AROUND ALL JOINTS.

MORE RUST FOUND IN SOME SILL AREAS TOO - NOW REMOVED AND REPLACED WITH

FRESH METAL.   BOTH DRIVE SHAFTS HAD BEARINGS PRESSED OUT, WERE THEN BARE-

METALLED, AND FINALLY REPAINTED. NEXT STAGE IS TO PRESS IN NEW UJ's 

FUEL PIPES (30/11/-0001)

THE FUEL PIPES AROUND THE FLOOR EDGE AREAS WERE QUITE RUSTY. WE

BARE METALLED AS MUCH OF THIS AREA AS IS ACCESSIBLE. ONE OF THE FUEL

LINES WAS BADLY CORRODED - SO REPLACED THIS SINGLE SECTION.

GENERAL SERVICING, SANDBLASING, WELDING (30/11/-0001)

QUITE A BIT OF RUST EVIDENT IN GENERAL APPRAISAL AT THE START OF

THE PROJECT IN APRIL. WAS DECIDED THE BEST APPROACH WAS TO GET

SOME TARGETTED SAND BLASTING, TO HELP FULLY EXPOSE THESE PROBLEM

AREAS.  ALSO, A CATCH-UP ON ROUTINE SERVICING NEEDED. TIRED SHOCKS

AND SPRINGS, CLUTCH FLUID ESPECIALLY VERY DECAYED, AND GENERAL 

LUBRICANTS TO GEARBOX, DIFF ETC DUE FOR A CHANGE.