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So following the winter I now have corrosion on 3 doors, I had seen it on one door and replaced the door, I should however done much much more.
As it stands the material Jaguar used to damp sound holds moisture against the door, and the door sweats internally no matter how well drained you think it is - the result is premature failure of the galvanising.
The sign that you have a problem is blisters in the paint on the face of the door - and when that shows it is already game over. Not much point posting pictures - rust is rust.
So if you don't have any blisters showing on your doors get the panels off and get all Jaguar's sound proofing materials removed. Even if you find nothing wrong you can then treat the door and should you feel inclined replace the sound deadening material with something less likely to absorb or trap moisture.
I'll be replacing all four doors, if I decide to keep the car, but I ain't happy at the potential cost which exceeds £1500 - so don't neglect your doors if they're still good - get in there and make sure, do not judge with the soundproofing in place - remove it.
Wow. That really stinks. I've noticed more corrosion on my 2011 than I would've expected for the age of the car and the climate in which I live, which has been disappointing, but it sounds like I might need to do an even deeper dive to check out some of the more hidden areas.
Strongly recommended I'm afraid, disappointed is an understatement. I've treated everything and left the door cards off for now while I decide what to do. I had considered all new doors but that is stupid money and the wonderful tax man here in the UK has cut my monthly income by 10% so I can't justify it. Right now I'll probably take the car off the road - may sell it on - not decided - I'm committed financially to the XJS and am at a point where it must be the priority. Love the SV8, it ticks all the boxes - at least it did.
I can take some pictures if you want to see the extent of this.
..... I'll be replacing all four doors, if I decide to keep the car, but I ain't happy at the potential cost which exceeds £1500 - so don't neglect your doors if they're still good - get in there and make sure, do not judge with the soundproofing in place - remove it.
Sorry to hear about this. When I first owned Jaguars in the early 1970's, they used to start dissolving from the sills up in little more than three years with the combination or poor build quality, rain and road salt but I thought JLR had finally left those problems behind after XJ40.
Normal practice with accident repairs was to re-skin a door instead of replacing the entire shell. Door skins used to be very cheap and I thought this was going to be a low cost solution for you but the cost now is outrageous. A front X250 skin is 569 UKP from Jaguar and a rear is 524 UKP.
Absolutely outrageous for sure and that's why I have shelved the plans - that's over 2k without paint and labour - so you could add another 1k to that, take a look at the cost of complete shells - it is eye watering, crazy as this may sound my XJS doors are in better condition and they're 35 years old ... I have owned this car a long time, every time I drive it I know why I bought it, but as it stands today we aren't friends and it may be time to go our separate ways - if anyone wants to get themselves an SV8 and leave behind a much older Jag 'classic' let me know.
Here are some pics of the door internals, sorry these aren't great, I tried to get the blistering on the outside to show but for some reason the camera refuses to see it. Either way if you look at the door skin inside surface all those dark patches are rust where the galvanising has failed due to prolonged contact with moisture - and no the door drains were / are not blocked. Although the doors were galvanised they never bothered their backside to paint them. The dark patches although it isn't clear are also deeply pitted in spots and this has essentially pinholed the door and blistered the paint on the outside.
In the images shown I have removed the sound damping material, sanded and treated the area with Aquasteel to hopefully inhibit any further deterioration although it is inevitable I guess now unless I tear the paint off the outside also and treat the face of the doors - all in all pretty depressing. I am stuck at a point where I cannot spare the funds to fix this and I won't drive it in this condition such is the OCD about such things.
Has anyone else seen this sort of blistering on the doors? Mine is 12 yrs old, daily driven through the high salt winters here in NE USA and I've not seen any rust issues
Wondering if we think this is a common issue or maybe a build quality issue at some point.
Apologies for the necro-bump but in light of the lack of response to others seeing it, I've got some interesting news. I've got it. And I've also got an SV8. Now in the UK, the SV8 is a very rare care. I've owned mine since 2010 (clearly I love it) and I've only ever seen two others on the road. I think they made 400 for the UK. I have exactly the same issue on both right hand doors - drivers and passenger. Much worse on the driver side. I'll be removing the sound proofing as advised and reskinning both doors when funds allow. Mine is a very early car, originally marked as Jaguar Engineering in the log book, so I wonder (and hope) that whoever signed off that procedure was duly slapped and sent over to Land Rover for their crimes before the bulk of production ramped up.
Mine is the same, two front doors have rusted from the inside out, it’s a shame as the rest of the car is lovely, it’ll be too much to sort out, so just living with it at the moment.
Usual 'it isn't a widespread problem' - except it is a widespread problem but that is an inconvenient truth - a bit like the excessive battery drain that many even here are in denial about - a battery that is unable to start the car after in three weeks of non use is excessive drain - tthe XF had this, the XJL was worse, no more 'modern' Jags for me.
That is very odd, never seen any of our cars do that and I'm in an area where it rains 9 months out of the year daily. Did your car have the plugged drain holes on the doors? That was the only issue I saw with XF doors and they would fill with water but never corrode like that.
Door Corrosion Warning
