Author Topic: Starting the final assembly on the E-Type - updated 4-6  (Read 37585 times)

Offline jabberwoki

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Re: Starting the final assembly on the E-Type - updated 12-12
« Reply #135 on: December 16, 2015, 01:13:35 AM »
Damn damn damn that looks pretty, too nice to drive.
Your motivating me to pull my finger out.
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Does the need justify the want ? Or does the want suffice?

Offline goodfellow

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Re: Starting the final assembly on the E-Type - updated 12-12
« Reply #136 on: December 18, 2015, 05:44:42 PM »
I had some time yesterday and today to tackle one of the hardest jobs of installing a Jaguar XK engine in an E-Type body; the torque reduction plate, transmission mount and lower transmission splash shield. It's basically a fiddly frustrating job that never seems to go well the first time round.




The transmission mount needs to be compressed, while the center mount shaft needs to protrude through the center of the mount. So a regualar jack is out of the question. I opted to compress the mount using two bottle jacks (one on each side) to get it up far enough on the transmission to enable the bolts to get a bite.





There is a lot of pressure required to compress that spring and inner rubber mount



Next up was the splash shield. This is not a big deal, but since the torque reduction plate sits directly in front of it, it must be installed at this point because once the plate is in place the shield can't be installed.



Now comes the torque plate itself. It straddles the subframe rails, provides an anchor for the torsion bars, and also ties the lower subframe mounts to the body. This usually not a big deal, but since this car has undergone significant body work and welding, there is always a chance that the lower dimensions have changed somewhat -- which would make it very difficult to tie that plate into six body and subframe mounts. They all must align perfectly or that plate won't fit.

I lucked out in that I only had to scrape off some of the thick bedliner undercoat to make the plate fit into that tight space. Still, it took several hours to make it properly line up and bolt in place.



Finally the chassis ground strap was installed to make sure the electrical system was able to do its job.



Lastly the drive shaft was installed and the car is basically a full roller.

Next up under-hood wires, brackets, relays, and accessories. -- Onward!

Offline pepi

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Re: Starting the final assembly on the E-Type - updated 12-18
« Reply #137 on: December 18, 2015, 06:53:01 PM »
Interesting way of doing that, spring looks stout and can put up a good fight. Once again man beats machine ..... thumbsup2 They always surrender the only question, is how long it will take. th-wink
Self-esteem: Does not make up for a lack of common sense. There is such a thing as a stupid question.

Offline goodfellow

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Re: Starting the final assembly on the E-Type - updated 12-18
« Reply #138 on: December 20, 2015, 05:30:53 PM »
Worked a few hours to mount the accessories. It is obvious that the Series II cars with AC, Power Brakes, and Power Steering posed a big problem to Jaguar. They used a very haphazard way to mount and position these additional options because of underhood space constraints. All this "engineering" resulted in a very complicated mounting bracket design that is very difficult to position and attach to accessory drives.

This is the bracket in question ...



... part of it mounts directly to the block, while other mounting points must include water pump, power steering pump, and alternator bolts.

First up the power steering pump -- it can't be installed after the fact. Its primary mount is on the timing chain cover (see the missing bolt in the pic)





Then the "Frankenbracket" is installed with one specific top bolt that doubles as a water pump bolt with a washer/spacer. Notice that washer spacing in between the waterpump housing and the bracket itself. Without that washer, the bracket won't clamp on the water pump bolt and a leak might occur.





The top of the bracket serves as the alternator mount --



Below is a short mount for the upper power steering pump, while a long spacer is installed at the lower side of the pump to mount it to the timing chain cover bolt





Lastly I mounted the alternator. That was the easiest job of the day -- LOL



Done for today, but the front of the car is starting to look like a Series II E-Type





I'm waiting for two more secondary wiring harnesses that go under the hood -- once they arrive I can start laying out the electrical circuits in the engine compartment.

Onward!


« Last Edit: December 20, 2015, 05:35:31 PM by goodfellow »

Offline mrchuck

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Re: Starting the final assembly on the E-Type - updated 12-20
« Reply #139 on: December 20, 2015, 07:15:19 PM »
Are the electricals still Lucas?
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Offline brslk

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Re: Starting the final assembly on the E-Type - updated 12-20
« Reply #140 on: December 20, 2015, 08:12:38 PM »
Looking really great Ray. I can't wait to see a video of it running.
I'm just a guy in a garage with some tools...

Bruce.

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Re: Starting the final assembly on the E-Type - updated 12-20
« Reply #141 on: December 20, 2015, 09:52:57 PM »
Are the electricals still Lucas?

Yup -- everything is Lucas    panicx panicx panicx

Offline goodfellow

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Re: Starting the final assembly on the E-Type - updated 12-20
« Reply #142 on: December 20, 2015, 09:54:31 PM »
Looking really great Ray. I can't wait to see a video of it running.

Slowly getting there Bruce. One more major hurdle to cross -- the interior. I've never done any significant interior outfitting, and this will be a learning experience.

Offline fatfillup

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Re: Starting the final assembly on the E-Type - updated 12-20
« Reply #143 on: December 21, 2015, 09:10:10 AM »
Ray, I am amazed at the knowledge you have about these cars.  IIRC, you worked on them professionally decades ago so some knowledge would be expected to be retained but man you know details that just blow my mind.
That scalloped box end is one of the few BB features that doesn't make Elroy puke

Offline mrchuck

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Re: Starting the final assembly on the E-Type - updated 12-20
« Reply #144 on: December 21, 2015, 09:31:03 AM »
Lucas Electrical back in the early 60s was affectionately called the "Prince of Darkness".
cannot suffer fools happily.
"Always great to save USA made tools."

Offline goodfellow

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Re: Starting the final assembly on the E-Type - updated 12-20
« Reply #145 on: December 21, 2015, 09:32:28 AM »
Ray, I am amazed at the knowledge you have about these cars.  IIRC, you worked on them professionally decades ago so some knowledge would be expected to be retained but man you know details that just blow my mind.

I worked on British cars back in the late 70's Phil, but without good notes, lots of digital pics, and the internet I'd be lost. I often look over the old threads on the GG to remind myself of what the heck was going on with a particular part or system when I was taking it apart.

Offline goodfellow

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Re: Starting the final assembly on the E-Type - updated 12-20
« Reply #146 on: December 29, 2015, 07:03:07 PM »
Today I had enough time to lay out the main body harness in the engine compartment. I've had a chance to look at several offerings from various vendors that specialize in E-Type harnesses, and although they are all quite good, they do not have the same wire gauge thickness that was installed in the car originally. I know these are aftermarket, but the last time I installed a new harness (back in the late 1980's) you could still get an OEM Jaguar harness from the dealer, and it matched the original.



Laying these things out is no easy feat. Unlike many of the domestic harnesses, these are unmarked, and in many instances the color codes have changed when compared to the original wiring diagrams. Jaguar uses a unique wide "zip-tie" like system to fasten the harness to the frames, but instead of using up my new OEM ties, I loosely installed the harness with regular zip ties because there are many tweaks and bends needed to do a proper install.



I also installed the old piston-type AC compressor. It's quite impressive -- LOL





One of the many oddities with a series II  E-type is that AC and Power Steering was really an afterthought, hence some strange mounting choices had to be made. Case in point is this bracket that bolts to the exhaust manifold on one side and is used to secure the rear of the AC compressor. It's a real pain to install, and if the compressor were improperly aligned, the vibrations may cause the bracket to come loose and cause and exhaust leak.



Once the compressor was installed, I could plan the harness routing through the front of the frames. A jumble of hoses and suspension parts makes this a little difficult -- but the harness is cut very well to feed the accessory leads to the proper end-points.









The frames have appropriate clips for holding the harness in place, but for now they will not be used until all the circuit runs are properly fitted and positioned.



Two publications that I can highly recommend when assembling an E-Type are a large color coded wiring diagram from ClassicCarWiring.com, and the SNG Barratt Group "Parts Collection" manual. Two great resources that make the identification of sub assemblies and parts a whole lot easier.





Onward!!

Offline Muddy

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Re: Starting the final assembly on the E-Type - updated 12-29
« Reply #147 on: December 29, 2015, 10:38:36 PM »
sharepopcorn
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Offline fatfillup

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Re: Starting the final assembly on the E-Type - updated 12-20
« Reply #148 on: December 30, 2015, 09:03:56 AM »

Laying these things out is no easy feat. Unlike many of the domestic harnesses, these are unmarked, and in many instances the color codes have changed when compared to the original wiring diagrams.


I can see it now, GF engages the turn signal and the wipers come on lolx
That scalloped box end is one of the few BB features that doesn't make Elroy puke

Offline pepi

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Re: Starting the final assembly on the E-Type - updated 12-29
« Reply #149 on: December 30, 2015, 10:31:15 AM »
Say that is coming alone well, wiring is always fun.....
Self-esteem: Does not make up for a lack of common sense. There is such a thing as a stupid question.

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Re: Starting the final assembly on the E-Type - updated 12-29
« Reply #149 on: December 30, 2015, 10:31:15 AM »