I have a 67 XKE roadster type 1 in good running condition but there is some rust showing on the bottom side sills. Has anyone personally had such work done on their XKE for this problem. What would be the cost range to replace such metal. I have had the car 20 years and it is garage kept. My goal is to make the the car structural sound with all good metal,then have a good paint job (I am not looking to turn it into a concourse show car restoration. I certainly like the car but am not willing to put in more than it would be worth after completing such work.I am in NJ but would be willing to travel a bit if there is a viable solution.

Any help would be greatly appreciated

Art

Submitted by NE52-32043 on Tue, 10/28/2003 - 16:14

Art,

Excellent! Let us know how things go. If your experience is anything like mine was, you'll end up not only with a great car but a new good friend as well. Terry is a great guy, and his wife Karen is absolutely wonderful too.

Steve Weinstein, JTC-NJ
'72 E-type 2+2
'70 XKE FHC

Submitted by mcload@ev1.net on Thu, 10/23/2003 - 10:33

Art:
Rusty sills (and rust in general) are nothing new to a 30 year old E-Type. Keep in mind that Sir William never intended E-Types to last very long. I've seen some catastrophic rust decay and others very mild. A lot depends on how the car has been stored over the past 30 years. Although rust in the sills is not a good sign, it may not be as severe as you think. If you have not done so already, you need to remove the seats, carpets, boot trim, gas tank....anything that keeps you from inspecting the sheet metal throughout the car. If the floors, driveshaft tunnel, and rear wheel arches are "crusty" rusty as well, then yes, you have a major problem. But the sills alone are not that big an issue. You really won't know the extent of damage until you remove them. Be certain to take it to a qualified and experienced E-Type shop. Do not remove the bonnet as the new sills need to be installed with the proper gap from the bonnet.

Your OTS is a beautiful and highly sought after machine. Solving rust problems like this are part of E-Type ownership and maintenance. Indeed, almost any classic car is going to have these problems. Since you have owned the car for 20 years, now is not the time to give up on it. Do it right and take your time. If you just take it to a shop for them to do all the work, then yes, you will pay dearly. But if you are mecahically inclined, you can save A LOT of money by doing the prep work yourself. Since you're going to repaint the car, you might as well do it right by removing the engine, bumpers, gas tank, trim, door handles, etc. Take lots of pics before removing intricate assemblies. If the car has undercoating, you really need to strip it as well to get to the clean metal. If you are going to change colors, then almost everything should be taken off the car and re-sprayed. One way to tell if a paint job is original (or well done) is to look under the instrument panel and in the center instrument console. Often times these areas are not re-sprayed because the owner doesn't want to go to the extent of work to remove the wiring harness. At the very least, you should consider replacing the engine harness. Anyway, I could go on and on. Visit my website for what you may be up against: www.mcload.com
It just takes time and perseverance, but your E-Type is worthy.

Patrick McLoad
1966 E-Type, Right-hand Drive Roadster
#1E1445, 2002 C5 National Champ

Submitted by mfrank@westnet.com on Tue, 10/21/2003 - 14:46

I can only add this to Steve's comment: E-Types tend to rust from the inside out. So the problem you see may mean there's more trouble on the inside of the sill. I'm afraid you won't know the damage until the sills are opened. Sheetmetal: cheap materials and labor: $$$.

Mike Frank

Submitted by NE52-32043 on Mon, 10/20/2003 - 12:22

Art,

I hate to be the bearer of bad tidings, but rust in the sills could potentially be the sign of serious problems. E-types do not have a frame. The structural integrity of the car is based on the monocoque, primarily the sills below the doors on both sides. If you are seeing rust in the sills, chances are pretty good that the condition inside is worse than it looks on the outside, as these sections tend to rust from the inside out.

That said, replacement sills are available and can be installed to put the car back in tip top shape. At the same time, appropriate rust proofing measures can be taken to assure that it doesn't happen again. But this work should be done by someone who is very familiar with these cars and who knows how to do it and what needs to be done. Don't just take it to a local body shop that will simply fill it with Bondo and paint it. You're asking for big trouble if you do.

I'd strongly suggest that you talk to Terry Lippincott at Lippincott's Garage in Sinking Spring, PA. (610-678-6775) (NAYYY, just a very happy customer). Terry rebuilt my Ser. III car after hitting a deer last fall. He does excellent work and really knows these cars inside and out. And his rates are very reasonable. Wherever you take it, make sure that they really know E-types and do the job right!

Steve Weinstein
'72 E-type 2+2
'70 XKE FHC