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My Interceptor MK2 rebuild

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by Gav » Sun Feb 23, 2020 5:21 pm

I got the fuse box wired up today. I had heard from other people about wiring connection issues to the light switch and overheating of the light switch contacts so I have taken the precautionary measure of fitting slave relays in line to the head light low/high beam fuse supplies, so now the feed from the light switch and high beam foot switch just trigger the relays. I have now routed power to the slave relay switch contacts from the Brown/white feeds from the alternator output supplies into the fuse panel. I have also fitted an over ride relay so the head lights can not be left on if the ignition switch is in the off or radio only position. With these relays in place, the light switch and the wiring loom behind the dash will now have 20 Amps less running through them with lights on and engine running. I have kept the side lights running direct from the light switch as then I still have a park light facility. The original looms on the car where all good with minimal heat hardening and conductor oxidation so they have been reused but all connector receptacles replaced and soldered after crimping. The fuse holders have been renewed and the original metal canister relays all opened up, contacts cleaned and metal canisters re-plated. It’s all a bit of a tight fit but the fuse panel still closes nicely.
Now on to connecting up the head lights!
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by Dion » Sun Feb 23, 2020 6:25 pm

Looking very tidy and well sorted, good work. Love the transparent connectors, where did you get those?
The future ain’t what it used to be.

67 Interceptor 117/2610
68 Interceptor 115/2943
other british old cars
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by Gav » Sun Feb 23, 2020 8:04 pm

Hi Dion, thanks for the comments, the Flag terminals come from RS Components, terminal part no. 488-1336 and cover part no. 488-1342.
I think you have to order each of them as a bag of 50. They also do the Flag terminal crimping pliers but they are a bit pricey and can probably be got cheaper elsewhere.
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by Gav » Sat Feb 29, 2020 1:27 pm

I had my NOS XJ6 LHD master cylinder delivered today from the USA. I think this falls in to the “Hens Teeth” category. A straight forward fit and now I can start laying in the brake pipes. The Master Cylinder that I had reconditioned from the car and didn’t use was a lucas/Girling part number 74660212 and the Master Cylinder just fitted is part number 74660213. You can see from the first photo how tight the front outlet of the master cylinder was to the upper chassis Leg of the inner wing. When this was originally retro fitted, the insulation on the chassis leg had been removed and the leg had been hammered in to provide clearance for the front brake pipe to clear. I was not going to repeat this. Now fitting the brake pipes will be easy.
Attachments
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by KaranMK2 » Sat Feb 29, 2020 6:21 pm

You are doing a fantastic job Gav. Quality is exceptional.

Kr
Karan
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by Gav » Sun Mar 08, 2020 10:08 pm

At last the engine bay is ready to drop in the engine and gearbox. The engine has been run for 1 1/2 hours after its rebuild so just need to change out the break in oil and build up the ancillaries prior to fitting. I ran the engine with the original points distributor but I will replace this with a new pointless distributor once back in the car. The original distributor has a solenoid retard system within the vacuum advance mechanism which does not work and also the diaphragm has gone rock hard so no functional vacuum advance. An NOS replacement from the states is going to cost over £300.00 delivered!
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by rta50car » Mon Mar 16, 2020 1:08 am

Looks Great - Very Professional !
1969 Mk 1 Jensen Interceptor Chassis number 115/3227
1951 FX Holden
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by AndrewP » Mon Mar 16, 2020 9:54 am

Hi Gav,

Looks amazing!

Just making sure, but those hoses between the Master Cylinder and the reservoirs are brake fluid safe?
Normal brake or fuel hose will not work for long, crack and then ruin your fantastic paint job.

Cheers
Andrew P
Perth, Western Australia.
Interceptor Mk3 #1284312
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by Gav » Mon Mar 16, 2020 1:23 pm

Hi Andrew, fear not, it’s the proper stuff, acquired on my last visit to Marin Robey. I became aware of the need for special hose for the reservoirs whilst reading up on other members restorations and repairs. Being a regular browser of everyone’s members pages has helped me enormously to avoid making mistakes or making wrong choices during this rebuild. The JOC Forum has been invaluable!
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by VFK44 » Mon Mar 16, 2020 11:33 pm

Normal brake or fuel hose will not work for long


I give up - I can't imagine why normal flexible brake hose will not work for reservoirs. I would have happily fitted that and not known any better. What is the "special hose" required?
"It is a mistake to try to look too far ahead. The chain of destiny can only be grasped one link at a time."
Sir Winston Churchill
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by AndrewP » Tue Mar 17, 2020 3:05 am

VFK44 wrote:
Normal brake or fuel hose will not work for long


I give up - I can't imagine why normal flexible brake hose will not work for reservoirs. I would have happily fitted that and not known any better. What is the "special hose" required?


Don't give up!!!

Sorry...my bad. I didn't mean to include brake hose in that statement.
It's where people use fuel/vacuum/coolant hose for brake fluid where it fails and leaks.
Andrew P
Perth, Western Australia.
Interceptor Mk3 #1284312
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by VFK44 » Tue Mar 17, 2020 1:23 pm

Whew! I do find the hardest to locate is vacuum hose for the servo. A lot of hose on offer by specialists for this purpose is not officially rated for vacuum use. Even a Pirtek salesman offered me some unrated hose, and when I queried it, he just said, "feel that hose: there's no way that will collapse with a bit of vacuum". I agreed, but it did seem odd.
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Sir Winston Churchill
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