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XJ13 Wiring Begins!

A well planned and carefully constructed wiring loom is critical to the success of any car build. The use of high quality connectors, the right automotive cables, the correct crimping equipment and crimping techniques are key. Its also important to create a drawing or "run list" so that the wiring loom and main connectors can be determined. This also ensures that changes or additions can be easily made in the future.

We really enjoy wiring up our vehicles. Looking under or behind a dashboard and seeing all the cables laid out neatly and logically is very important. We also ensure that the harness is designed with bulkhead connectors in firewalls and panels. Various harness fastening clips are used to ensure it stays in place. Every harness should be able to be disconnected and removed from the vehicle. We do not make looms that require cables to be cut to remove them from the vehicle. This helps during construction as the looms can be made out of the vehicle in a neat and concise manner and fitted to the car.

Of particular importance is the planning and execution of the dashboard wiring loom. Many of our vehicles have removable dashboards and we wire those through one or two large connectors so that they can be quickly and easily removed from the car. We also use multiplexing systems in some vehicles to reduce the number of cables to and from dashboard switch-gear.

We like to start with the dashboard when wiring the car. It tends to be the most complex part of the wiring so we enjoy doing that first. The dashboard wiring for the XJ13 can be seen below.

Some wires are labelled on the dash to help the owner identify on some of the more critical wires.

We use Deutsch connectors for most of the interconnects in the vehicle. They are highly reliable, sealed and we have a good range of them in stock.

We use the correct terminals and crimping techniques for each of the cable sizes used throughout the vehicle.

The dash harness plugs into the main under dash fuse box assembly. Again this can all be easily removed from the vehicle to work on it.

For quick changes or to service on the XJ13 a fuse the panel can be flipped up from under the front hood and checked without crawling under the dash.

All wires are left un-taped in internal areas where protection is not required. It makes future changes much easier. We also don't need to tape as there is no mess to hide.

We also installed a remote battery disconnect to enable the electrical system to be isolated from within the car. We ensure these disconnects incorporate bleed down resistors so that alternators are not damaged and internal ignition cut circuits to eliminate engine run on.

Mega and Midi fuses are also used to protect main power feeds from the battery and alternator. Where cable assemblies will be exposed to debris in wheel wells etc. we cover the harnesses.

Main battery looms also use pass-through connectors in firewalls to ensure they can be easily removed and will not chafe and short to the chassis. All signal wires use double shielded Teflon insulated tin plated multi-core cables. These are very compact and ensure light reliable looms can be built.

The heat shrink boots on all the large connectors are not installed and shrunk down until the car is completed. We also run additional spare cables through the vehicle to assist with future additions.

With the majority of the wiring completed attention will soon focus on the interior trim

Win Car Insurance Competition

Thanks to our FOXY Lady Insurance partner, Cornmarket Insurance Services, we are announcing a special insurance competition so that one UK female insurance policyholder can win up to £500 worth of car insurance at renewal time in 2018.

All you have to do is REGISTER FOR AN INSURANCE QUOTE (car, home, motorcycle or pet) – and read the Terms and Conditions on that page please.

We don’t promise that we can beat ’em all, but depending on perceived risk factors and during changeable market conditions, we are one of the only insurance services (if not the only?) to ring fence a totally female portfolio when it comes to motor, home, motorcycle and pet insurance.

Which is a good thing in most instances.

And there’s more.

An added bonus for non members

If you have yet to join FOXY Lady Drivers Club, just register for an insurance quote and enter this competition to receive a FREE Online Member gift subscription to FOXY Lady Drivers Club into the bargain. This makes you eligible for our Member Only insurance services.

If you are a member of FOXY Lady Drivers Club, please tell any female friends who aren’t.

We do this because only women can legitimately be members of a motoring club so we can then reserve our preferential insurance rates/services for female members of the Club. Who can then add partners and husbands of course. But not boy racers.

Sadly statistics confirm that it’s still young men that cause the majority of (and the most expensive) road accidents.

And being a motoring club for women drivers, our road safety advice and support services put women first and we don’t want to have to pay for these expensive male accidents.

Don’t miss out. We exist to save savvy Club members money. The more that join the Club the better the deals we can negotiate across the board. To benefit us all.

FOXY Steph

Building a Functional XJ13 Dashboard

Only one XJ13 was ever built and the dashboard layout was not that functional. The speedometer was all the way on the LHS of the vehicle and there were no gauges behind the steering wheel. As always with replicas there is room for some changes but you have to be careful not to ruin the feel of the original. Dashboards are one of those items that can have some changes but I feel switch gear and other details should be like the originals or the car can loose some of its identity. Below is a photo of the original XJ13 owned by Jaguar.

The client was happy to create a dashboard that had as many original details as possible however he wanted the speedometer and tachometer behind the steering wheel. I agree that this is a change that makes the dash way more functional.

We purchased an array of Lucas flip and push button switches that were close to or identical to the original car. They look great but can be terribly unreliable out of the box so we always have extra on hand! We also sourced a fuse holder and indicator switch that is similar to the original.

The client also supplied a real Russian fighter timer to populate the LHS of the dash where the tachometer was originally. Its a really nice addition to the dashboard.

After designing the layout the dashboard openings were cut out carefully as the dash was supplied in a painted state.

We measured the space behind the dash for the tachometer and speedometer and it was very tight but the new technology gauges would just fit. The speedometer is a GPS unit and the tachometer fully electronic. Maybe this is why the original car did not have gauges here!

Some of the switches required the fiberglass dash to be thinned out carefully to allow the front rings to be tightened.

Aluminium brackets were manufactured to supp port the dashboard in the car.

The Russian timer looks great on the dash and next was to wire it up.

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Maruti Electric Car – Make IN India

On Thursday, Maruti’s Japanese owner Suzuki has announced to produce its first commercial Electric car in India. For this Suzuki has decided to invest about $600 million to its Gujarat based facility in Hasalpur, which houses Plant A with annual 2.5 lakh capacity and produces Baleno. A new plant B with similar capacity will come up by 2019 and will be followed by a Plant C. This new commitment will take Suzuki total investment in India to $2.1 Billion alone in Gujarat.

Maruti Electric Car

Suzuki has produced Swift all electric version called Swift REEV but never produced it commercially. Suzuki Motors has decided to make Gujarat the manufacturing base for its electric car business. The new EV will not only sold in Indian market but also will be exported. This new plant will help bolster efforts for Indian governments flagship Make In India progem. It also gives a push to switch to more cleaners fuels for transport.

Its noteworthy that last week Tata Motors has also announced to go for an all electric Tata Nano. Where as Mahindra and Mahindra has decided to enter Cab Aggregators sector with new electric car.

A major significant investment will be to establish a new combustion engine unit at same facility of about 5 lakh capacity.  Apart from the new electric car Suzuki has announced a JV with Japanese Toshiba and Denso to produce electric Li-ion battery pack for electric vehicle in India.

Future for Electric Vehicles

A Stanford economist, Tony Seba, thinks that the global oil business will end as soon as 2030. In a study released recently, Tony talks about the revolutionary changes soon to be wrought by electrification of the transportation. The study published by Stanford University says that fossil-fueled cars will vanish within eight years and the people who want to buy cars will have no choice but to invest in electric vehicles or vehicles working on similar technologies. Tony says that this is because the cost of the electric vehicles; which includes cars, buses and even trucks will decrease and this will result in the collapse of the petroleum industry.

Indian Government has also shown proactive approach towards electric cars. In January 2017, the Indian government announced to bear up to 60% of the research and development (R&D) cost for developing the indigenous low-cost electric technology. Power minister Piyush Goyal in March said, “We are working (on the scheme). Can we actually give electric car for free (zero down payment) and people can pay for that out of the savings on the petroleum products? Innovation is possible, it just needs an open mind. You need to think of scale and be honest.”

 

The post Maruti Electric Car – Make IN India appeared first on Auto Glass Masters.

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V12 Engine Installation in the XJ13

This XJ13 will be equipped with a worked 6.0lt V12 engine and is mated to a new Oerlikon Graziano 6-speed transaxle as used in the Lamborghini Gallardo. A bare block was used to begin the design and fabrication of the engine mounts. Due to the tight clearances of the transaxle and the mounting constraints a rigid mount system was required.

This rigid mount setup is similar to the mounts on the GT40 and it is surprising how little vibration there is with such a setup.

First step was to install the adapter plate to the block to allow the Jaguar to bolt to the transaxle.

The engine block could then be lowered into the rear of the car.

Once installed the space available for the engine mounts could be established.

Careful measurements allowed the chassis and engine block to be modeled in CAD and a simple engine mount concept developed.

The engine mount was developed with features to assist in alignment during engine installation. A mock-up was then made to ensure all was OK before laser cutting the parts.

The mount components were positioned for TIG welding.

After cutting an access hole in the chassis for the chassis backing pates for the engine mounts it was felt that the chassis needed bracing were the mounts were bolted to the chassis. A large brace that triangulated the side and base of the chassis was fabricated and installed.

This effectively distributed the engine mount loads over a larger chassis area to unsure that chassis deflection was kept to a minimum.

After torquing both sides of the mounts it was good to see that the main bolt could slide out on either side of the chassis. Everything was aligned well without residual stresses.

While its a tight fit the engine is level and the sump clearance is good.