fabricate

Window channel felt

The chrome frame, or channel, for the windows has a groove that is filled with 3/16″ black felt that both protects the glass and provides a smooth sliding surface. The old felt was badly soiled and had pulled away from the frame in some areas. To make sure the new......

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Ventilator glass seal

See also no draught ventilator post. As part of the no draught ventilator restoration, we decided to replace the seals that hold the glass pane to the chrome frame surround. They were dirty and missing in some sections. This requires a roll of 3/64″ glass setting tape, a tacky black......

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Speaker mounts

Sometime in the mid-1970s, a Japanese radio and Pioneer speakers were installed in the Jaguar. The speakers were fastened to the side panels and positioned over the circular cutout in the chassis sheet metal. The 6 1/4″ cutout can accept modern 6 1/2″ speakers although the bolt pattern must be......

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Microphone holder

The Alpine double-DIN unit includes a small cylindrical microphone to communicate with Apple Siri and other apps. A black plastic clip (for a visor or steering wheel) comes with the unit, but it is not appropriate — from both an esthetic and functional viewpoint — for the Jaguar. The microphone......

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Trimming the fan

See prior discussion of fan conflict with the brake servo. How to trim a stamped steel fan with twisted blades? It can’t be held in a bench vice. An attempt to mill the fan on a rotary table failed because the extended blades created too much “chatter” against the cutting......

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Fuel system boot connections

Installation of the petrol tank allows us to complete the fuel system connections in the boot. The fuel level sending unit is connected by three wires: a black ground that fastens to one of the unit bolts; an orange wire attaches to the “W” terminal for the fuel warning light;......

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Overdrive oil drain plug tool

In preparation for testing the starter motor (before the engine is put back in the car), the engine and gearbox were filled with oil — Brad Penn 20W-50 partial synthetic racing oil for the engine, and Lucas 80W-90 gear oil for the gearbox and overdrive unit. The listed capacities are......

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Shut face panel door fillers

One of the quaint Jaguar Mark 2 details are four little filler pieces fitted on the “shut face panel” of all four doors. Made of aluminum, each piece has a handmade wood plug fastened to the door panel with #5 wood screws. These fillers could be painted the body color......

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Clutch slave cylinder return spring

See also overview of the gearbox-overdrive restoration. The clutch slave cylinder should have an external spring to help bring the release bearing mechanism back to its starting (that is, clutch engaged) position. These somewhat delicate springs tend not to survive well, and ours didn’t. The spring attaches to a small......

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Heater lever labels

Jaguar placed the heater lever labels on the inside edge, sandwiched between the radio, with HOT-COLD on the left and CAR-SCREEN on the right. Never easy to read, especially at night without illumination, these labels were mostly reminders to the owner about what the levers did. As previously discussed, the......

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