Metal Workshop Update -August 2025
Currently, in our metal workshop, we are working on a wide variety of restoration projects, including a full metalwork restoration for a 1950 Jaguar XK 120, a new chassis for a different 1953 XK 120 and aluminium seats for a Jaguar MK2. The two key areas of craftsmanship in the XK 120 full restoration are the hand-fabricated aluminium wings, replacing the original steel wings and reconstructing all the body panels before reassembling. Our senior panel beater, is working on this project. They is utilising his 35 years of experience in the trade to construct the body panels, ensuring an efficient and high-quality restoration.
The Jaguar XK 120 was produced between 1948 and 1954. The XK 120 was the first post-war Jaguar sports car. Produced with a steel body, this model was only intended to be a limited-production model; however, high demand led to full-scale production. This model was fitted with a 3.4 inline-6 engine producing 160-220 horsepower, reaching a top speed of 120 mph. These Jaguars go from 0-60 mph in 10 seconds. The XK 120 was one of the fastest production cars of its time, winning multiple endurance races, proving its spectacular performance.
The original XK 120 would have been fitted with pressed steel wings, but in this restoration, handmade aluminium replicas have recently been created at the P&K Thornton workshops. Our panel beaters reconstructed the wings using aluminium, this offers several benefits, including weight reduction and improved performance and handling capabilities of the Jaguar XK 120. Additionally, this reconstruction improves corrosion resistance, supporting its long-term preservation.
To reconstruct the wings, our panel beater began with a flat aluminium sheet, which was shaped using the English wheel, a classic tool in a coachbuilder’s toolkit. This can be a long, tedious and complex process, because our auto body technicians need to create compound curves that match the flowing lines of the original bodywork. After the wings are shaped, individual sections are then TIG welded together and dressed to an authentic finish, ensuring they not only look correct but also fit the original mounting points and body lines of the Jaguar precisely.
The steel front and rear panels of the XK 120 often suffer from corrosion due to years of exposure to moisture, road debris and ageing under seal. To begin this restoration process, we removed and inspected the panels for rust, distortion or previous poor repairs to assess the damage. During this process, we will decide whether the corrosion can be cleaned, or if it has structural corrosion, if so, parts of the panel will need to be cut out and replaced or fully refabricated. After the front and rear panels are restored, we will begin to go through the same process with the body panels, and we are preparing all the panels to be reassembled. This process requires a lot of precision and skill from our master craftsmen to ensure the lines and proportions match the original design of the XK 120 perfectly.
In addition, another Jaguar XK 120 is in our workshop at the moment for a chassis replacement and body adaptation. The second XK 120 is having the core structural framework restored. Some of the work being undertaken in this chassis reconstruction includes aligning the chassis to the original factory measurements and adapting the mounting points to ensure the old body shell fits securely and correctly onto the new frame. After that, our auto body technicians reinforce and weld brackets or tabs where necessary, whilst ensuring the suspension geometry, drivetrain alignment, and body mounting are all correct.
Additionally, our coach builders have recently finished reconstructing seats for a Jaguar Mark 2. Throughout this restoration, tradition and precision are blended seamlessly during the reconstruction process to create the bespoke panels. Using the original Jaguar Mark 2 seat pattern as templates, new frames have been built to mirror the construction of the originals as closely as possible. The frames are fabricated from shaped aluminium and welded to match the dimensions, angles, and support structure of the period seats. To maintain the structural integrity of the Mark 2 and to replicate the original manufacturing methods, a wire edge will be fitted around the perimeter, helping to reinforce the seat frames. Not only are our panel beaters taking care to replicate the details of the original seat, but they have additionally tried to match the weight of the original steel seats to ensure the Jaguar maintains its intended balance and driving characteristics.
This stage of both XK 120’s restorations highlight the skills required by our coach builders. By using lightweight, corrosion-resistant materials, like aluminium, with traditional shaping and welding methods, the Jaguar XK120 maintains its period-correct aesthetic whilst boosting performance and durability. If you are interested in any custom metalwork, covering anything from full restorations, repairs and bespoke builds from the ground up for your classic car, please contact us with confidence! If you have any further enquiries, please call us on 0115 926 2266 or email us at info@thorntonrestorations.com.