I recently had to replace the large coolant hose (inserts under thermostat housing) as it ruptured after rubbing against a protruding metal brace in the front of the engine compartment in my 2001 XK8. Some have tried grinding this metal down as apparently the is not uncommon. Does anyone have a simpler fix, perhaps some kind of rubber patch on the metal???. I am not interested in grinding metal!

 

How about wrapping the hose where it contacts that area? You could make several sleeves to fit over that hose using something like an old bicycle tire tube. Or you could wrap it in layers of duct tape. Just be sure to check it occasionally so you catch any wear before it gets through the sleeve to the hose itself....

 

I've seen this reported before and checked my hose. Thankfully it is fine. It's close but won't contact that protruding part. It seems that the connection of the hose at both ends is critical to get the routing past that protrusion without touching it. It might be worth unclamping one end and twisting the hose gently to adjust the routing. You may loose a small amount of coolant but it should be doable.