• Advertisement
Xclusively Jaguar
SNG Barratt
David Marks Garages
Make a donation to XJ40.com

XJ40 Turbodiesel

BiTurbo228
Posts: 130
Joined: Wed Jul 09, 2014 10:52 am

Re: XJ40 Turbodiesel

Postby BiTurbo228 » Wed Sep 01, 2021 11:45 am

To fit the new roof skin I laid the old one over the top to cut it to shape, being quite generous with the overlap so I didn't cut off too much. Then I took it on and off the frame over and over shaving little bits off the edges each time until I had a really nice fit. Slow and methodical was the order of the day.
Attachments
Roof 36.jpg
Roof 36.jpg (301.8 KiB) Not viewed yet
Roof 37.jpg
Roof 37.jpg (95.49 KiB) Not viewed yet
Roof 38.jpg
Roof 38.jpg (106.87 KiB) Not viewed yet
Roof 39.jpg
Roof 39.jpg (105.59 KiB) Not viewed yet
Roof 40.jpg
Roof 40.jpg (89.2 KiB) Not viewed yet
'92 XJ40 - currently turbodiesel-swapping
'87 X1/9 Turbo
'74 Spitfire 6
'66 Triumph 2000
'98 MGF VVC
'90 Alfa 75 24v
'92 BX TZD

BiTurbo228
Posts: 130
Joined: Wed Jul 09, 2014 10:52 am

Re: XJ40 Turbodiesel

Postby BiTurbo228 » Wed Sep 01, 2021 11:49 am

With that all fitting rather nicely it was a case of slowly tacking everything together, working around the perimeter of the roof one tack at a time to allow the other areas to cool. Took the best part of a day, but worked really nicely :) unbelievably easier than the fillet panel, although still needed a delicate and meticulous touch.

It's interesting how wonky these roof panels are out of the factory. One side of the frame was much closer than the other on both the new and old roof panels, although they seemed to look fine from the outside :lol:
Attachments
Roof 35.jpg
Roof 35.jpg (120.98 KiB) Not viewed yet
Roof 41.jpg
Roof 41.jpg (110.17 KiB) Not viewed yet
Roof 42.jpg
Roof 42.jpg (114.77 KiB) Not viewed yet
Roof 43.jpg
Roof 43.jpg (121.31 KiB) Not viewed yet
'92 XJ40 - currently turbodiesel-swapping
'87 X1/9 Turbo
'74 Spitfire 6
'66 Triumph 2000
'98 MGF VVC
'90 Alfa 75 24v
'92 BX TZD

Aidan
Posts: 921
Joined: Fri Jun 26, 2009 11:57 am
Location: Tonbridge, Kent

Re: XJ40 Turbodiesel

Postby Aidan » Wed Sep 01, 2021 3:16 pm

Professional looking job there! It looks like it's a much better idea to go the whole hog and replace the entire roof skin instead of faffing around with a sunroof panel.
And who needs an English wheel when you have a Greek parts supplier :) .

Regards
Aidan

1994 Moroccan Red XJ40 3,2 Sport ("Ruby")
1995 Jade Green X300 3,2 Sovereign ("Jade")
2005 Cedar Green Pearl Volvo XC 90 SE - Sold
2007 Colorado Red Ford Galaxy Ghia

BiTurbo228
Posts: 130
Joined: Wed Jul 09, 2014 10:52 am

Re: XJ40 Turbodiesel

Postby BiTurbo228 » Tue Sep 14, 2021 12:14 pm

Aidan wrote:Professional looking job there! It looks like it's a much better idea to go the whole hog and replace the entire roof skin instead of faffing around with a sunroof panel.
And who needs an English wheel when you have a Greek parts supplier :) .

Regards


Thanks man! There was definitely a 'I'm about to make a £90 mistake' thought running through my head as I started cutting, but it all ended up quite well!

Would be lost in so many ways without Naki :D

One of the things that I did to stop myself going mad during the roof bashing marathon was every now and again divert myself onto smaller tasks that were a bit more straight forward. One of those was getting the gearstick sorted. £45 got me one of China's finest floor mounted E36 gearsticks, which I was pleasantly surprised was put together quite well! I'm sure it's not as nicely finished as something 3x its price, but it works, the bearing is smooth, and it will do as a basis for modification.

First up was to do a little CAD modelling and cut the base plate to shape:
Attachments
Gearstick 1.jpg
Gearstick 1.jpg (52.22 KiB) Not viewed yet
Gearstick 2.jpg
Gearstick 2.jpg (147.85 KiB) Not viewed yet
Gearstick 3.jpg
Gearstick 3.jpg (150.4 KiB) Not viewed yet
Gearstick 4.jpg
Gearstick 4.jpg (229.6 KiB) Not viewed yet
Gearstick 5.jpg
Gearstick 5.jpg (190.69 KiB) Not viewed yet
'92 XJ40 - currently turbodiesel-swapping
'87 X1/9 Turbo
'74 Spitfire 6
'66 Triumph 2000
'98 MGF VVC
'90 Alfa 75 24v
'92 BX TZD

BiTurbo228
Posts: 130
Joined: Wed Jul 09, 2014 10:52 am

Re: XJ40 Turbodiesel

Postby BiTurbo228 » Tue Sep 14, 2021 12:15 pm

Next was to clearance the gearbox tunnel a little for the captive nuts and carefully weld the plate in place.
Attachments
Gearstick 6.jpg
Gearstick 6.jpg (198.96 KiB) Not viewed yet
Gearstick 7.jpg
Gearstick 7.jpg (167.39 KiB) Not viewed yet
'92 XJ40 - currently turbodiesel-swapping
'87 X1/9 Turbo
'74 Spitfire 6
'66 Triumph 2000
'98 MGF VVC
'90 Alfa 75 24v
'92 BX TZD

BiTurbo228
Posts: 130
Joined: Wed Jul 09, 2014 10:52 am

Re: XJ40 Turbodiesel

Postby BiTurbo228 » Tue Sep 14, 2021 12:18 pm

With that sorted, I thought I didn't really like the idea of the bearing just being open to all the road grit and muck chucked around under the car so I should make some seals. This is the idea I came up with for the underside. Little bolt-through plate clamping some rubber sheet to hold the grease in.
Attachments
Gearstick 8.jpg
Gearstick 8.jpg (153.92 KiB) Not viewed yet
Gearstick 9.jpg
Gearstick 9.jpg (148.61 KiB) Not viewed yet
Gearstick 10.jpg
Gearstick 10.jpg (162.61 KiB) Not viewed yet
Gearstick 11.jpg
Gearstick 11.jpg (133.56 KiB) Not viewed yet
'92 XJ40 - currently turbodiesel-swapping
'87 X1/9 Turbo
'74 Spitfire 6
'66 Triumph 2000
'98 MGF VVC
'90 Alfa 75 24v
'92 BX TZD

BiTurbo228
Posts: 130
Joined: Wed Jul 09, 2014 10:52 am

Re: XJ40 Turbodiesel

Postby BiTurbo228 » Tue Sep 14, 2021 1:21 pm

Next up was modifying the little linkage that connects the gearstick to the gearbox which was way too long. I'm not sure I've got the offset right even after a couple of attempts, but it's close enough for a test to see if I can get the gears ok (I think the offset affects how much distance there is as you go sideways across the gates).

Oh and it hasn't grown in size, they're different vices! :D

Lastly I had a bit of a brainwave about an upper dust boot. I'd bought a universal CV boot a while back that never ended up being used, and if I put a lip on the upper side to locate it I could probably make that work there.
Attachments
Gearstick 12.jpg
Gearstick 12.jpg (141.11 KiB) Not viewed yet
Gearstick 13.jpg
Gearstick 13.jpg (139.72 KiB) Not viewed yet
Gearstick 14.jpg
Gearstick 14.jpg (145.83 KiB) Not viewed yet
Gearstick 15.jpg
Gearstick 15.jpg (201.11 KiB) Not viewed yet
'92 XJ40 - currently turbodiesel-swapping
'87 X1/9 Turbo
'74 Spitfire 6
'66 Triumph 2000
'98 MGF VVC
'90 Alfa 75 24v
'92 BX TZD

BiTurbo228
Posts: 130
Joined: Wed Jul 09, 2014 10:52 am

Re: XJ40 Turbodiesel

Postby BiTurbo228 » Tue Sep 14, 2021 1:28 pm

We're jumping ahead a bit now to a job I've only just done, but in the interest of updating on the gearstick all in one go...

I'd picked up a really nice gear knob from a chappy in the States (via Etsy). It's a lovely piece of work, but being for an automatic it's quite lightweight. Having replaced the weighted gear knob for the original Getrag 'box I know how much a little bit of heft really helps a gear change feel nice. So, I found a sheet of lead and got snipping :)

I snipped up lots of little squares of lead and dropped them down the threaded section into the void behind it. There wasn't much space, but enough to add a bit of weight. It ended up at 85g once I'd poured some 2k gloss down to bind everything together. Doesn't sound like much, but in the hand it feels a appreciably heavier.

Next up was to chop off the M14-ish thread on the BMW gear stick and drill/tap an M8 thread for a stud to screw the Jag gear knob onto.

et voila! Looks the business I think :)
Attachments
Gearstick 16.jpg
Gearstick 16.jpg (187.68 KiB) Not viewed yet
Gearstick 17.jpg
Gearstick 17.jpg (106.02 KiB) Not viewed yet
Gearstick 18.jpg
Gearstick 18.jpg (101.95 KiB) Not viewed yet
Gearstick 19.jpg
Gearstick 19.jpg (99.34 KiB) Not viewed yet
Gearstick 20.jpg
Gearstick 20.jpg (140.32 KiB) Not viewed yet
'92 XJ40 - currently turbodiesel-swapping
'87 X1/9 Turbo
'74 Spitfire 6
'66 Triumph 2000
'98 MGF VVC
'90 Alfa 75 24v
'92 BX TZD


Return to “Jaguar XJ40 Gallery”

Who is online

Users browsing this forum: No registered users and 2 guests