XK8/XKR Convertible Top Replacement - Update
 

I've been slowly (moving at a snails pace) replacing the convertible top on Craigslist Cat. So far, it has been a fun learning experience and no real unexpected instances other than learning to cut the rear glass out of the windshield frame, and finding rusty corrosion under the seals, which I'm in the process of removing rust and repainting.

Not sure if the corrosion found is typical as this was A) A Car Semi Close to the Florida Gulf Coast and B)Left outside the last couple years of it's short 18k mile life.

After I'm done, I will document the full details so far, you have to take your time, etc., but someone with patience and a friend at times, could do it. One thing to note, there is no way I could figure to save the outer seal, as that donkey is glued in and at the age, etc, you're biting the 90+ dollar bullet to just replace. Probably best anyway since it's so much work to get it in and out.

Enjoy!

https://cimg3.ibsrv.net/gimg/www.jag...f5079aedf9.jpg
I found a piece of chalk in the under neath header panel from the factory - pretty cool!
https://cimg4.ibsrv.net/gimg/www.jag...aa5acf95af.jpg
https://cimg5.ibsrv.net/gimg/www.jag...196f8aae86.jpg
Seal removal
https://cimg6.ibsrv.net/gimg/www.jag...fed3428d19.jpg
https://cimg7.ibsrv.net/gimg/www.jag...d7e645c6b3.jpg
Using a push tool to push "cheese wire" through seal to other side.
https://cimg9.ibsrv.net/gimg/www.jag...12cff93718.jpg
Using a push tool to push "cheese wire" through seal to other side.
https://cimg0.ibsrv.net/gimg/www.jag...13aa57820b.jpg
Using a push tool to push "cheese wire" through seal to other side.
https://cimg1.ibsrv.net/gimg/www.jag...7c7e94586f.jpg
https://cimg3.ibsrv.net/gimg/www.jag...ed3b3f901c.jpg
https://cimg8.ibsrv.net/gimg/www.jag...b2b1557ae3.jpg
https://cimg0.ibsrv.net/gimg/www.jag...8319723aa3.jpg
Glass Frame Rust
https://cimg1.ibsrv.net/gimg/www.jag...ab8082a69d.jpg
https://cimg2.ibsrv.net/gimg/www.jag...977483ac92.jpg
https://cimg1.ibsrv.net/gimg/www.jag...99b0c76ffe.jpg
https://cimg4.ibsrv.net/gimg/www.jag...c661bb1020.jpg
Glass Frame Rust
https://cimg5.ibsrv.net/gimg/www.jag...c2aef465dd.jpg
Glass Frame Rust

Update, continuing the slow crawl of top replacement. I'm definitely not quick, but I don't know how a shop would have handled the rust in my top frame.

I cleaned all the residue and old sealant material off the top frame, need to fill some pits with JB Weld and sand smoother then paint the frame. Also spent a while getting the new top into the lower holding frame. This job is a PITA. Do not attempt if you have arthritis or need more hand strength, as you have to curl the top around into the groove and slide in, all while using a rubber mallet and plastic drift in places.

https://cimg2.ibsrv.net/gimg/www.jag...54cb6fcc98.jpg
Frame cleaned up after wire brush, ready to be filled and painted
https://cimg3.ibsrv.net/gimg/www.jag...b4a28421c3.jpg
Frame cleaned up after wire brush, ready to be filled and painted
https://cimg5.ibsrv.net/gimg/www.jag...7cf5b038f8.jpg
Convertible top and Frame
https://cimg7.ibsrv.net/gimg/www.jag...54eca6cb0a.jpg
Convertible Top and Frame. Using the pool table as a large clean surface.
https://cimg7.ibsrv.net/gimg/www.jag...20b6bcad57.jpg
Correct way to loop top around and into groove, using a plastic drift and rubber mallet at places. Tedious process!

Almost one month since and....
 

Keep at it.

Looking forward to the the next update. 🤔

Tick, tick.....

Hang in there. Looks like your are well on your way to a solid repair....

Done this 4-5 times on Miatas, MGB, 71 Corvette. It can be a daunting task but they all came out great in the end and saved a ton of money. Take you time and measure 5 times before you cut. Frame should be blasted clean or at least sanded rust neutralized prime and painted. Careful not to bend the frame it can be fragile and difficult to get back into shape if it gets out of line. Lots of photos prior to disassembly (as you have done) always helps when you are trying to reassemble several weeks later. I have found the most difficult part to be the inside liner tough to get it perfect but never done a Jag so hopefully its easy. Best of luck can’t wait to see how it comes out.