Author Topic: Starting the final assembly on the E-Type - updated 3-1  (Read 7647 times)

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Offline goodfellow

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Re: Starting the final assembly on the E-Type - updated 2-19
« Reply #60 on: March 13, 2016, 01:06:33 PM »
Nothing much to report. Work commitments shut me down for two weeks, but I was able to get back on it this weekend. Late Series II E-Types are a lesson in frustration during re-assembly because the factory manuals don't accurately reflect every model year exactly. That's because so many changes were made during their last few years of production that it was impossible to keep up with the sheer number. Years ago at a Jaguar car show I was told by a gentleman that had worked at Jaguar during these years, that many changes were often made right on the factory floor, and that these inconsistencies were never documented at all. I can see why -- the electrical circuit diagrams that are officially published sometimes do not match what's in my car.

I did manage to get the engine compartment electrical runs correctly positioned and connected to battery posts and external voltage regulator. The connectors were dirty and corroded, but they cleaned up well, and new boots were included in a new grommet kit.









Battery terminals were re-crimped and cleaned up and the grounds were fixed









The corroded door switch assemblies were disassembled, cleaned and painted, then reinstalled with new barrel connectors.





The steering column support will also cleaned and repainted --



The original rear connector harness were cleaned, re-wrapped in places, and replaced in their respective channel runs.





Finally -- and this is the hard part, the dash center panel connections are being tested to make sure the feeder circuits are all in order.



Lots more to do -- frustrating at times, but every day I get to work on this makes it a bit more fun.


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Re: Starting the final assembly on the E-Type - updated 2-19
« Reply #60 on: March 13, 2016, 01:06:33 PM »

Offline fflintstone

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Re: Starting the final assembly on the E-Type - updated 3-13
« Reply #61 on: March 15, 2016, 12:09:49 PM »
it is good to make forward progress.
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Offline goodfellow

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Re: Starting the final assembly on the E-Type - updated 3-13
« Reply #62 on: March 29, 2016, 08:22:40 PM »
Had to take a week off from this project to do some traveling for work, but got back on it today. Tracing the circuits is tough, but so far I'm OK with my wiring routes and terminations. I also added the vent hoses -- which have to be threaded in-between the wiring harnesses and the panels. This stuff is really frustrating to get right.



The vent pipes terminate in three bulkhead holes that are the air intake plenum built into the firewall. The fan and heater core are attached to the outside of the firewall and feed the plenum with either hot or cool air through the heater unit.





The vent pipes are pretty easy to install initially, but very hard to route properly through the wiring harnesses.







The speedometer assembly was installed next --





Some loose ends to tie up, but the steering wheel assembly and glove box are next.

Onward  --


Offline rusty

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Re: Starting the final assembly on the E-Type - updated 3-13
« Reply #63 on: March 31, 2016, 07:34:42 AM »
Looking good. Have you decided what the next project will be yet?
Tool do job=Good tool

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Offline fflintstone

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Re: Starting the final assembly on the E-Type - updated 3-13
« Reply #64 on: April 02, 2016, 07:39:43 PM »
boy that looks like a lot of work.
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Offline goodfellow

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Re: Starting the final assembly on the E-Type - updated 3-13
« Reply #65 on: May 07, 2016, 04:45:43 PM »
Been a while since I updated this thread --- well, I've been busy work wise trying to add a few shekels to the old retirement account, and there was not much time for garage work. Work is over and time to hit this project again.

First up, I needed to address a major issue: front and rear bumpers. The rears were totally corroded and I tossed them into the scrap heap when I started this project. I managed to find a good used set, but as you can see it's not in pristine shape. My estimation is "fair" condition at best, but the price was $300 and that was a steal. Rusted on the inside a bit, but the outside shows just a few scratches. I'm glad to get it at this price because a new rear set would come close to $1500.











Obviously the "new" bumper is not perfect -- so I have to clean them up and decide on how to address the chrome issues. To be honest, a good chrome job would be pretty much close to a new aftermarket bumper set. So my options are to consider the new "Chrome Paint" process which is very popular in the restoration community.

[youtube]https://www.youtube.com/watch?v=TYMLTvDDNM8[/youtube]

If this process (or a similar method) is available in my area, I will definitely consider it. If anyone has any input on this process please let me know. A second alternative is to do a DIY chrome paint job on the bumper and live with an aluminized finish.

Finally the rear light will need to be installed -- but they must be installed once the bumper is in place. So for the next few weeks I will concentrate on the bumpers.







The rear wiring harnesses have been run and now the lights and accessories will need to be tested and installed.





Looking forward to get on this and to into the garage. First order of business is to get the garage clean. After a few weeks of inactivity the place is a dusty and dirty mess.

Onward!!

Offline fflintstone

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Re: Starting the final assembly on the E-Type - updated 5-7
« Reply #66 on: May 11, 2016, 04:39:58 PM »
It took a few days to figure out my password and reply to this. I truly hate all the Microsoft updates that kill my forum cookies.

The process looks similar to PDV chrome that is used on some wheels now. They tend to be about 20% cheaper than real chrome. On the Corvette forums the PDV is generally not looked upon favorably. Apparently there is a longevity issue and a lack of luster compared to real chrome. There is a really good large scale chrome place I think in Tennessee. I don’t know about prices. 

That would be an ideal process for your light housings though. Levels above chrome or aluminized paint.
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Offline goodfellow

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Re: Starting the final assembly on the E-Type - updated 5-7
« Reply #67 on: October 13, 2016, 06:27:39 PM »
Been a while since I've updated this thread. I was unable to get much garage time this summer due to some back problems -- I just had to veg and sit on the couch until I healed up. This project is about four/five months behind -- so I better get my rear in gear and start to detail out this car a bit.

First up were the rear tail lights. I did extensive work on these a few years back and they look good, but they needed new lens gaskets. Well imagine my surprise when my supplier told me that they were not available and none were forthcoming soon. Only place I found was in England and they wanted a fortune. On a concours resto this is a no-brainer, but on my DIY driver, it's just too much money. I looked around for a cheaper solution and found foam window seal -- same width and diameter as the OEM gasket and it sticks -- $6 for a roll at Home Despot --- SOLD.

Original gasket was trash



Window seal to the rescue









Works great and is very pliable and you can make just about any lamp or lens gasket with this stuff, and it allowed me to install my rear light assemblies.





Second item was installing the DIY AC hoses that I made a few months ago. I must say they fit pretty darn good.











Onward -- next I need to run fuel, brake, vacuum and EVAP lines.


Offline goodfellow

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Re: Starting the final assembly on the E-Type - updated 5-7
« Reply #68 on: October 13, 2016, 06:28:13 PM »
First a little side project -- this stupid piece of plastic is the bane for many E-Type owners. It's a cheap little cover shield for the fan motor connections to keep dirt/debris out of the terminal. Problem is that it's is so cheap that it always breaks at the slightest touch and most Jags don't have them anymore. I decided that I wasn't going to buy these gems from the OEM -- but make my own.



I used a broken old OEM cover as a template for a pair of new ones.



Plastics have come a long way since the 60's and I found a plastic binder in my office that had just the right thickness, and most importantly, the pliability to stand up to the heat and elements under the bonnet. Plus the material looks a lot like carbon fiber -- you can't see that well in the pic, but it does look great.





The shield is attached to the rear bolts on the fan motor.







Next up the brake lines, EVAP lines, and fuel lines. My original lines were trash, but several years ago I found these OEM lines at a local swap meet. They looked terrible (dirty, grimy), but the previous owner had enough foresight to paint them before he installed them. That was not a Jag factory practice, but that paint kept the things from rusting. All I had to do was strip off the grime and paint them fresh. OEM lines are definitely better than fabricating my own. Even the retaining clips were in great shape.





Once they were stripped of paint, the steel was nice and fresh and ready for new paint.



I used silver brake caliper paint and it does the job.







The rear brake line connects at the brake pressure light switch -- and since it's OEM, it's a quick tight fit.







It locks into a bracket in the rear tub



I did have to fab the rear tub crossover for the EVAP cannister in the trunk. I used the old rusted piece as a template.





The lines were run along the body stiffener rail using the old clips.





The EVAP line begins at this front vapor cannister and ends at the rear vapor cannister located in the trunk floor .





Next up the fuel line -- after a little cleaning/wire wheeling and paint it looks better than new. But I need new clips, they are on order from NAPA and should be here tomorrow.





This line requires OEM fittings and is expensive if new, so a used line saves a LOT of $$. I bough all three lines for less than $25. It pays to look at swaps.





Throwing some caliper paint on the line.





Finally the vacuum tank fitting and hoses were cleaned. The hoses are OEM Girling and I had replaced them less than a year before tearing this car apart. They are dirty, but they cleaned up very well.







Almost done with replacing all the hard lines -- Onward!


Offline goodfellow

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Re: Starting the final assembly on the E-Type - updated 5-7
« Reply #69 on: October 16, 2016, 07:51:15 PM »
Just to finish this hardline section out -- the fuel line went in perfectly. It wasn't originally from this car, but the bends and the length were almost custom. The only problem I had was fitting the rear. I had to remove the rear sway bar to snake that large line over the IRS housing and through the trunk floor bulkhead.

Sway bar came out in just a few minutes --



rear bulkhead fuel line junction  --



Perfect bend around the rear tub, and nice straight runs along the stiffener. During the resto I welded all the old mounting holes closed because they were all wallowed out from years of overtightening and using the wrong screws. These clips were fastened with self tapping sheetmetal screws.









Botton hardlines are done and now on to fine detailing the rest of the engine compartment and installing the fuel tank - Onward



Offline goodfellow

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Re: Starting the final assembly on the E-Type - updated 5-7
« Reply #70 on: March 06, 2017, 03:25:24 PM »
I've been remiss in posting, but to be honest, most of the last month was dedicated to circuit tracing. The wiring problems that I discovered in this car were just too tedious to post anything of true interest. This weekend it came down to the last critical bits. Installing the gas tank and the vapor canister. There is nothing more frustrating than installing an E-Type tank because the space is just so limited. Add in the continuous fiddling with maintaining the position of the rubber gas tank mounts while trying to squeeze this pig into that tiny space --AND installing the fuel filler neck hose at the same time; let's just say that there is a lot of cursing involved in getting this job done.

The first problem that I tackled (and deviating from standard Jag practice) was to forgo using the thick moisture trapping padding for the insulation of the lower trunk space (the lower boot). This padding caused the tank to rust out in the first place. The pic shows the old thick padding that acts like a sponge for water condensation and is the major cause of rust in E-Type fuel tanks. A new interior kit includes this type of padding, but I won't use it.





Instead I used an aluminized insulating foil with a tar-like backing. Heat the tar backing with a heatgun and it becomes sticky and very adhesive.





In addition I replaced the old vapor cannister hoses with fresh tubing, but I saved the old tubing restrictor check valves (simple orifices designed to reduce the airflow in the tubes) and reinstalled them in the new tubing.



All that old hardened spaghetti tubing mess was replaced with nice new tubing.



While I was in there, the interior dome light was connected and tested....



... and finally the tank was fitted. I even managed to get it installed with a minimum of paint coat damage. This tank support bracket was the last piece to go in --





The car has an appointment in two weeks to get the front end aligned and to get a final electrical check by a qualified old-time Jaguar specialist. Hopefully he will find no major issues.

The last item to get installed this week is the AC module -- hopefully it will be a smooth run.

Offline fflintstone

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Re: Starting the final assembly on the E-Type - updated 3-1
« Reply #71 on: April 03, 2017, 10:23:39 AM »
What is the aluminum sheet with tar? (bitumen)? I could use some of it. I use the foil/sticky foam stuff (frost king duct insulation) for a sound deadener, but this would be better in a few places.
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Offline goodfellow

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Re: Starting the final assembly on the E-Type - updated 3-1
« Reply #72 on: April 08, 2017, 07:03:26 PM »
What is the aluminum sheet with tar? (bitumen)? I could use some of it. I use the foil/sticky foam stuff (frost king duct insulation) for a sound deadener, but this would be better in a few places.

I think it is -- it was sold at the local hardware as outdoor duct insulation. I bought a huge role some years ago, and am still using it.

Offline fflintstone

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Re: Starting the final assembly on the E-Type - updated 3-1
« Reply #73 on: August 30, 2017, 02:18:47 PM »
Any updates? saw a jags at Woodward dream cruise.
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Offline goodfellow

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Re: Starting the final assembly on the E-Type - updated 3-1
« Reply #74 on: August 30, 2017, 03:27:39 PM »
Nope -- had a few BIG house expenses (new roof), and had to rebuild my daughter's car after an accident. That put a crimp in the Jag budget. Will get back on it in September when the garage/tool account is replenished to where I can get new parts.