Vintage Car Works of Englewood, Colorado contacted The Metal Surgeon to enlist our help on restoring this Jaguar XK120 truck lid.  The trunk skin was in fairly bad shape, as you can see from the photos.  We discussed re-skinning the trunk lid, but if the original was salvageable it would be preferable to go that direction.  After taking the trunk lid back to our shop and inspecting it closer, we decided to restore the original.

Our first step in the approach, is to remove the bondo from the skin without disturbing the aluminum.  Secondly, we metal finish the skin using a spoon, various hand weights and a file.  Once the metal finishing is in the closing stages, we then TIG welded the license plate holes, as the plate will eventually be relocated.  The metal finishing process is continued to completion as shown below.

The whole process shown below took 15 hours start to finish.

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Jaguar XK120 in restoration process

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Damaged Jaguar trunk skin

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A close up of the damage

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First stage metal finishing

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AC TIG welding of license plate holes

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Metal finished to completion

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Trunk lid delivered and on the Jag

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