Tim9

Hey does anyone have the factory manual and or pics for for pulling out the dash? I only have the Max Ellerys one and it is not very clear. If someone could scan that in and put it up as a sticky that would be great! Cheers, Tim

Regarding the Passenger side footwell. This could be the same issue as the rusted plenum, however it sounds like the heater core, mine has just gone. Try running water in the plenum grille below the windscreen only. If no water, clamp the heater hoses under the bonnet to see if it is still happening. You should smell coolant if it is the heater, and you said it smells a fair bit so sounds like coolant, also your coolant level will be dropping all the time as most of the coolant will be going out of the drain-hole that comes out of the firewall, (under the bonnet), that comes out just above your passenger side chassis rail, with a smaller percentage going into your footwell. I re-plumbed the inlet and outlet back into itself under the bonnet as a temporary fix, and will try the Resolene system sealant when I get a chance. Your heater won't work but it stops it leaking as a quick fix. Cheers, Tim

I cannot believe how these plenums are designed! If you pull off the windscreen wipers and the grille you will see what I mean!. They have a cover plate that runs over the top of the drain gutter in the plenum, next to the interior air inlet duct, designed especially to catch leaves and crap so your car will rust out in no time. To top if off there is no special seam sealer or rust protection in this area. Actually I think the cover plate must have bee some add on to stop water getting into the air inlet duct from turbulence in the plenum, some bright spark came up with that was cheap, it looks like some idiot just welded in a scrap bit of plate they found in the workshop in there. Also the paint from the factory does not reach in there very well at all, and the welds from the stupid plate over the gutter would accelerate the rusting. On top of it all it is almost impossible to get to this area without cutting away the top external panels, and even then the access is not ideal, you would have to attack it from underneath as well. There are rust repair panels for the (valance?) area in front of the windscreen. I initially wondered why they sold these panels as I have not seen many rusted there, now I realise that that is so you can get into the plenum and weld these back on. Apart from that the actual duct to the internal ventilation system in the plenum is great for attracting rust also. I have done a temporary fix, as mine was nearly totally rusted out and I needed to get it sorted quickly. I cut out the gutter cover plate with a dremel, small hacksaw, and angle grinder (be careful this is dangerous in the confined area, not recommended). Cleaned out the rust with a 3M stripper disk, (matted wire type). Did not cut any external panels. Used the KBS rustblast system to treat the metal, with black stuff as the final coat. Poured lots of that stuff in there to get inside as well and brushed what I could reach from under the dash. Then used the septone metal repair stainless steel matting, (like fibreglass but better). Reformed the gutter and sealed up all of the holes. Recoated with 2 coats of rust blast black. Now is all sealed up and protected until I want to get keen with pulling the interior out and start welding. Hope this helps.

Will it pass for rego. putting an aftermarket computer and throttle bodies on new motor? Not sure which State you are in.

Yeah the phase 5 does look good, I am thinking about that.

Looks good on the XF as it is more rounded at the front and has a flatter bonnet. The XE has a square centre raised bit. I was looking at the 70's mustang Boss 302 Double side slash and blackout. Though I am starting to think the shaker is the best way.

The car is yellow, so I am trying to reduce that with a bit of black as I think too much yellow does not look so good, a bit taxiish. But I think yellow can look good with a bit more black on the car.

Has anyone ever seen any decent looking bonnet blackouts or GT style stripes? All the ones I have seen look crap, but there must be a way to make them look good. Otherwise a Shaker or BA Bonnet Bulge does look good. I am tossing up my options.