Welding New Floor Pans Into My Jaguar XKR Restoration!

2026-09-02

Welding New Floor Pans Into My Jaguar XKR Restoration!

Channel: projects in the barn (3660 subscribers)

Most of today's crop is hashtag spam, shorts, or generic "learn welding" filler with zero substance. This Jaguar XKR restoration episode stands out as the only candidate that shows a real, sustained welding job with genuine context.

Floor pan replacement is one of the more instructive jobs in automotive restoration because it combines several skills that translate broadly: cutting out rusted sheet metal without warping surrounding structure, fitting new panels to compound curves, and welding thin gauge steel (typically 18–20 gauge) without blowing through. On a unibody car like the XKR, the floor pans are structural, so the welds have to be strong and clean enough not to distort the shell.

Expect to see plug welds or spot-weld replication along the seams where the original pan was pinch-welded to the rocker and transmission tunnel, plus stitch welding across the open seams to manage heat. Good restoration channels will also show seam sealing and cavity wax afterward — critical steps that determine whether the repair lasts five years or thirty.

A small-channel restorer working on a modern Jag (not the usual E-Type or MG) is refreshing, and the "barn project" framing usually means real-time problem solving rather than a polished shop production.

Why watch: A practical look at structural sheet-metal welding on a unibody car — a skill that applies to any rust repair job.

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