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XJ40 Turbodiesel

mikegamble
Snr Member
Posts: 318
Joined: Wed Jul 16, 2014 7:41 pm
Location: Penzance, sunny Cornwall

Re: XJ40 Turbodiesel

Postby mikegamble » Sat Oct 02, 2021 9:29 pm

I’ve just read this from start to finish - absolutely brilliant job!
Very impressed with your welding and fabrication - looking forward to seeing the finished product!!
Daimler XJ40 G531ABW Chassis No.603858
1986 Porsche 928 S2
1978 Mercedes 450 SLC
1986 Porsche 924S
1981 Porsche 924 NA
1991 Toyota Celica
1981 VW T25 rusty camper
2003 VW T4 Caravelle

BiTurbo228
Posts: 149
Joined: Wed Jul 09, 2014 10:52 am

Re: XJ40 Turbodiesel

Postby BiTurbo228 » Fri Oct 08, 2021 12:41 pm

Thanks man! It's getting rather close to being running and rolling now, although with the weather turning I expect it'll spend 6 months or so with ropey paint until I get that sorted. Will give some time for the finances to recover a little too!

Next up was replacing the fuel lines. The originals weren't in that bad condition, apart from the union to the fuel filter which had corroded to the pipe and sheared it rather than spin. Opted for 8mm cunifer which should have a longer shelf life. The BMW high pressure pump apparently likes to have 4 bar feeding it, but on the BMW there's a module that regulates the pressure by adjusting voltage to the pump. No good for the Jag and its walbro I think (although I do still have it just in case).

I looked around for 4 bar diesel regulators as I hear fixed ones are a bit more reliable than adjustable ones. The main one I could find is from a Land Rover TD5, but when you type 'TD5 fuel regulator' into google it autocompletes it as 'TD5 fuel regulator leaking', which I gather is a common problem. Will see how the malpassi does!

Next was masking up all the interior and giving the roof a blow over with epoxy primer, after discovering that the etch primer I used isn't waterproof :roll: I also tested out using a cavity wax injection gun to blow some paint into the sections of roof I can't reach. Seems to work rather nicely, although it does chew through paint!

That cured I could pop some dynamat on the roof. It adds in a bit of the weight I've just cut out with the sunroof, but it really does stop the panel ringing, and isn't actually all that heavy compared to old-school bonded tar sound deadening. About 500g per sheet.
Attachments
Fuel pipes 1.jpg
Fuel pipes 1.jpg (141.75 KiB) Not viewed yet
Fuel pipes 2.jpg
Fuel pipes 2.jpg (151.8 KiB) Not viewed yet
Fuel pipes 3.jpg
Fuel pipes 3.jpg (146.5 KiB) Not viewed yet
Roof paint 1.jpg
Roof paint 1.jpg (95.02 KiB) Not viewed yet
Roof paint 2.jpg
Roof paint 2.jpg (168.73 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

mikegamble
Snr Member
Posts: 318
Joined: Wed Jul 16, 2014 7:41 pm
Location: Penzance, sunny Cornwall

Re: XJ40 Turbodiesel

Postby mikegamble » Mon Oct 11, 2021 10:27 pm

Really impressed with this, especially as it started out as ‘merely’ an engine conversion and it’s almost become a full resto!!

Will be very interested to see it running ad in the road!

Keep the good work going!!
Daimler XJ40 G531ABW Chassis No.603858
1986 Porsche 928 S2
1978 Mercedes 450 SLC
1986 Porsche 924S
1981 Porsche 924 NA
1991 Toyota Celica
1981 VW T25 rusty camper
2003 VW T4 Caravelle

Wilfred88
Posts: 257
Joined: Mon Jun 23, 2014 11:05 am

Re: XJ40 Turbodiesel

Postby Wilfred88 » Tue Oct 12, 2021 8:07 am

Awesome project!

I really like how nice you make everything. It shows craftmanship.

BiTurbo228
Posts: 149
Joined: Wed Jul 09, 2014 10:52 am

Re: XJ40 Turbodiesel

Postby BiTurbo228 » Wed Oct 13, 2021 3:58 pm

Thanks guys! There's definitely a strong element of scope creep here :lol: My thinking is that I'm fed up with driving cars that I know there are major problems with, and just nursing them along until something finally does go and I need to rush to fix them (a situation wholly and entirely caused by my desire to drive cars that are at least 30 years old, and on the affordable end of the scale). I would like one car that's (at least mechanically) completely sorted and reliable to give me some headroom to fix one of the others.

This has all been accelerated recently by my last working car ('87 X1/9) popping its headgasket a couple of weeks back :shock: luckily I'm close enough now with the Jag that I can borrow one of my dad's cars while I finish that off, rather than diverting course to fix one of the others. It might not be painted, but it should be mechanically solid and the bare metal bits covered with epoxy primer!

Next thing off the list was the last of the sills repaired (although there's a bit of crust on the passenger's front that needed fixing, and some rusty bits right at the front). Starting to run out of rust to fix which is exciting :)

Ended up forming most of the panel in situ as, but turned out ok :) had to take the door off to get to the front section, but that's not too tricky with an extra pair of hands to hold the door while you unbolt it.

Remade the door seal retaining channel using my patented tent peg technique ;)
Attachments
Sills 1.jpg
Sills 1.jpg (165.02 KiB) Not viewed yet
Sills 2.jpg
Sills 2.jpg (155.72 KiB) Not viewed yet
Sills 3.jpg
Sills 3.jpg (167.17 KiB) Not viewed yet
Sills 4.jpg
Sills 4.jpg (148.95 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: 149
Joined: Wed Jul 09, 2014 10:52 am

Re: XJ40 Turbodiesel

Postby BiTurbo228 » Wed Oct 13, 2021 4:43 pm

Modified the technique slightly so I could form a full 180 degree curve. Ground a piece of flat bar to shape with a bit of a longer section below so you can clamp it higher. Managed to recover a curved section of the channel at the front which I didn't fancy making at all! A lick of epoxy primer to protect it and we're sorted.

I've also recently found that getting the shape of the channel right is critical to getting the seal to seat nicely. Initially I'd make it with a thin gap in the middle and test it with a seal, and only trim back enough so it's possible to fit the seal. Oh, and don't hammer it too tight as it'll push the seal out when you try to fit it. Tricky to explain!
Attachments
Sills 5.jpg
Sills 5.jpg (163.68 KiB) Not viewed yet
Sills 6.jpg
Sills 6.jpg (156.17 KiB) Not viewed yet
Sills 7.jpg
Sills 7.jpg (157.5 KiB) Not viewed yet
Sills 8.jpg
Sills 8.jpg (181.92 KiB) Not viewed yet
Sills 9.jpg
Sills 9.jpg (153.74 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

pimgmx
Posts: 3522
Joined: Tue Jul 08, 2014 12:07 pm
Location: South East of the Netherlands

Re: XJ40 Turbodiesel

Postby pimgmx » Wed Oct 13, 2021 6:37 pm

Impressive progress!

I guess you will be ending up with one of the most rust-less XJ40s on the planet by the time you're done!! :lol:

the daily: 01 S8 http://bit.ly/2kIwP4m
the eyecatcher: 93 Insignia http://bit.ly/1iGrmsU
the GT: 89 XJS http://bit.ly/1WQGpC5
the diva: 88 Biturbo SI https://bit.ly/3dzdvAL
the ex: 93 3.2 http://bit.ly/14GTNrq

panarabica
Posts: 171
Joined: Sun Apr 19, 2015 7:00 pm

Re: XJ40 Turbodiesel

Postby panarabica » Thu Oct 14, 2021 9:39 am

Wow, you are attacking that rust full scope! The sills did not look that bad, was it really necessary to cut out all that metal? How is the situation rust wise where the bulkhead meets the floor panel? Most of my 40's were rusting there nicely under the sealer.
Once the car is sorted you could post a video on you tube with a proper walk around explaining all the mods that you have done. Keep up the pace this is looking very promissing!

Rob
- Jaguar DD6 MY'93
- Mercedes S500 Lorinser MY'99
- VW Phaeton MY'15
- Mercedes S300 MY '67
- Mercedes SL280 MY`94
- Mercedes C220 MY'15

BiTurbo228
Posts: 149
Joined: Wed Jul 09, 2014 10:52 am

Re: XJ40 Turbodiesel

Postby BiTurbo228 » Fri Oct 15, 2021 11:28 am

Thanks guys! Yes it has turned into quite the rustathon (although it's still a lot lighter than the stuff I've done on my Spitfire, or have to come on the Triumph 2000...).

The rust on this particular panel wasn't to the point of having holes like some of the others, but wasn't a million miles away from it. It was sort of a case of 'while I was there I might as well make it good'. I expect there is rust along the bulkhead-to-floor seam as there's some crunchy bits of sealant there :? but unfortunately a pending house move is likely to cut fixing that short. I'm currently borrowing my dad's car as my Fiat X1/9 went pop so the Jag needs to be roadworthy pronto! It'll get chopped out and sorted later though.

A youtube walkaround is a great idea! Once it's all actually working I'll see what I can do :) I've got a gopro knocking around somewhere too so I should be able to get some driving footage as well!

Next up was the exhaust. To support the 400ish hp I want out of the M57 you really need a 3" system (or a 2.25" twin system). That's a fair bit fatter than the stock Jag exhaust which is around 2.25" for the single section and under 2" for the axle pipes (which would probably do fine if you're after 250ish hp from a basic remapped M57 or M57n).

So, first step was to shorten an affordable downpipe from eBay and swap the lower end slip joint for another v-band. I used gaffa tape to mock everything up, but on the next system I do I'll try and find a tape that doesn't have a bit of stretch in it as that often threw out the alignment.

That was followed by a long straight section to get past the gearbox mount which was a tricky section to clear, then a dogleg to avoid the handbrake mechanism.

I ummed and arred about getting a TIG to do this job, but in the end the cost and additional time to learn it just outweighed the expediency of using MIG. I was wondering about backpurging as well, but ended up not doing that either. From what I've read a well supported stainless system shouldn't suffer from cracking even if it's migged and not backpurged so I thought I'd test the idea.
Attachments
Exhaust 1.jpg
Exhaust 1.jpg (227.57 KiB) Not viewed yet
Exhaust 2.jpg
Exhaust 2.jpg (178.78 KiB) Not viewed yet
Exhaust 3.jpg
Exhaust 3.jpg (146.17 KiB) Not viewed yet
Exhaust 4.jpg
Exhaust 4.jpg (223.16 KiB) Not viewed yet
Exhaust 5.jpg
Exhaust 5.jpg (127.44 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: 149
Joined: Wed Jul 09, 2014 10:52 am

Re: XJ40 Turbodiesel

Postby BiTurbo228 » Fri Oct 15, 2021 11:34 am

From there it connects to another straight section and a splitter to head over the axles. I've used v-bands throughout and made it in a number of different sections so I can tweak it around for fitment which I did quite a lot!

The splitter section I made out of a 180deg 2.25" u-bend and ovalled the 3" tube in a vice until it mated up nicely.

With all of the front section at least tacked together I could test propshaft clearance with my patented carbon fibre composite prop (3" postage tube I had lying around :D ). Loadsa room :)
Attachments
Exhaust 6.jpg
Exhaust 6.jpg (192.1 KiB) Not viewed yet
Exhaust 7.jpg
Exhaust 7.jpg (143.72 KiB) Not viewed yet
Exhaust 8.jpg
Exhaust 8.jpg (249.69 KiB) Not viewed yet
Exhaust 9.jpg
Exhaust 9.jpg (169.21 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


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