My Interceptor MK2 rebuild

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Gav
Posts: 88
Joined: Tue Jan 09, 2018 11:47 am
Location: Gosport

Re: My Interceptor MK2 rebuild

Post by Gav »

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!
Attachments
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Dion
Posts: 1506
Joined: Mon Nov 21, 2005 2:00 pm
Location: Tilburg, Netherlands

Re: My Interceptor MK2 rebuild

Post by Dion »

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.

Interceptor Mk1 LHD & RHD
GT LHD
Gav
Posts: 88
Joined: Tue Jan 09, 2018 11:47 am
Location: Gosport

Re: My Interceptor MK2 rebuild

Post by Gav »

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.
Gav
Posts: 88
Joined: Tue Jan 09, 2018 11:47 am
Location: Gosport

Re: My Interceptor MK2 rebuild

Post by Gav »

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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KaranMK2
JOC Chairman
Posts: 1058
Joined: Fri Apr 21, 2017 7:51 am
Location: Milton Keynes

Re: My Interceptor MK2 rebuild

Post by KaranMK2 »

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

Kr
Karan
Gav
Posts: 88
Joined: Tue Jan 09, 2018 11:47 am
Location: Gosport

Re: My Interceptor MK2 rebuild

Post by Gav »

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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rta50car
Posts: 280
Joined: Sat Sep 27, 2014 8:57 am
Location: Arundel (Gold Coast), Queensland, Australia

Re: My Interceptor MK2 rebuild

Post by rta50car »

Looks Great - Very Professional !
1969 Mk 1 Jensen Interceptor Chassis number 115/3227
1951 FX Holden
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AndrewP
Posts: 715
Joined: Sun May 05, 2013 11:14 am
Location: Perth, W Australia

Re: My Interceptor MK2 rebuild

Post by AndrewP »

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
Gav
Posts: 88
Joined: Tue Jan 09, 2018 11:47 am
Location: Gosport

Re: My Interceptor MK2 rebuild

Post by Gav »

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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VFK44
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Re: My Interceptor MK2 rebuild

Post by VFK44 »

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?
"Now that chassis number is particularly interesting ‘cos it’s the one after the one before, which is the one after mine, not many people know that"
Stephen, Epping, Essex
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AndrewP
Posts: 715
Joined: Sun May 05, 2013 11:14 am
Location: Perth, W Australia

Re: My Interceptor MK2 rebuild

Post by AndrewP »

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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VFK44
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Re: My Interceptor MK2 rebuild

Post by VFK44 »

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.
"Now that chassis number is particularly interesting ‘cos it’s the one after the one before, which is the one after mine, not many people know that"
Stephen, Epping, Essex
Gav
Posts: 88
Joined: Tue Jan 09, 2018 11:47 am
Location: Gosport

Re: My Interceptor MK2 rebuild

Post by Gav »

So some real progress the last few weeks. I wasn’t brave enough to have a go at fitting the windscreen and tailgate window so after consulting the JOC Oracle, I had Autoglaze Wimborne come over and fit them which took them 2 1/2 hours, good job guys! This transformed the look of the car and re-invigorated me to crack on. I was never going to be able to fit the engine and gearbox as a lump in my garage so I dropped the gearbox in to the engine bay and slowly drew it back on a trolley Jack, locating it on its rear mount. I purchased a 2 Ton engine hoist from eBay which advertised a 1450mm boom. Once assembled it turns out that it only has 1040mm of useable boom before the hydraulic ram scrapes the car nose and you need a minimum of 1150 mm to get the engine in and still probably scrape the nose. I made a heavy duty boom and longer heavy box legs which gave me 1220mm and the engine dropped in a dream. The next few weeks should see the back axle and front suspension on the car, every thing is new or reconditioned to get these jobs done, it’s just a big boys Meccano kit now. The next photos should be of it sat on its reconditioned and re rubbered wheels; goodbye Jensen Gasser and hello cool Interceptor.
A few photos of the latest progress.
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Grant
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Re: My Interceptor MK2 rebuild

Post by Grant »

It's an absolutely beautiful stunning job you are doing there to my favorite model of Interceptor GavImage.. really stunning, you are very meticulousImage.. if only everybody was so fussy with everything and you could choose anyone of them to employ and have work beside you and trust them while you get on with something elseImage.. but after employing many staff in my younger days.. I never ever found oneImage!!!.. let alone a few to choose one from!Image..Wicked stuff Gav.. keep em coming my ole fruitImage
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Gav
Posts: 88
Joined: Tue Jan 09, 2018 11:47 am
Location: Gosport

Re: My Interceptor MK2 rebuild

Post by Gav »

I have been asked how I was able to run up the engine after rebuild. I made up a frame to mount the engine, gearbox, radiator etc and did all the break in running on this. The engine was fine but I did have a front oil seal leak on the rebuilt gearbox which was a 15 minute job to remove the gearbox and get it back off to the rebuilders. I hate to think how long this would have taken had it been back in the car when I found the problem. I did upload a clip of the break in to YouTube which you can view if you copy and paste” https://Youtu.be/ff2SAX7b_N4" onclick="window.open(this.href);return false; “ to your browser or search on YouTube for “ Jensen Interceptor Chrysler 383 engine running after rebuild “. I did try to upload it to the JOC forum but couldn’t get it to happen.
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