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 Rank: Super-Elite       Groups: Registered
Joined: 19/06/2013 Posts: 4,588 Points: 13,553 Location: West Yorkshire
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Issue 96
Contents: Left front bumper,Right front bumper,Rear reflectors x 2,Left rear light cluster,Right rear light cluster,Prop shaft,Replacement hose,Left bonnet retainer,Right bonnet retainer,Left rear light LED(labelled 08),Rear indicator LEDs(labelled 09),Right rear light LED(labelled 10),Screws
Gently pull off the hose between the engine and the header tank,replacing it with the one in this issue, which has one flattened end to clear the bonnet.
Take the dashboard assembly from Stage 65, and set the steering wheel in the central position, with the central spoke pointing straight down.Lift the end of the steering joint emerging from the bulkhead and check the alignment of the ‘D’- shaped socket . With the wheels pointing straight ahead, the flat side of the ‘D’ must be level and facing upwards for the steering wheel to align correctly.If it isn’t, remove the radiator (by undoing the two screws at the bottom), undo the two screws holding the offside steering rack bracket, and remove it.Undo the screw on the offside kingpin so that you can lift the end of the steering rack. This allows you rotate the column to the correct position, then reassemble the parts.Invert the body (taking care to protect the paint on the roof) and move the upside down dashboard assembly, towards the bulkhead.Fit the steering wheel into the socket easing the parts together as you move the dashboard assembly into position.Secure the dashboard assembly to the bodyshell with JD01 screws into the tabs shown and also into the holes near the passenger door and on the driver’s side.Double-check that the steering wheel aligns properly when the wheels point straight ahead.
Now take the four parts of the rear lights, plus two JP04 screws.Taking the reflectors which have a ‘D’-shaped fixing pin, press them flush into a matching socket in the light cluster.The cluster is then pressed home into a shaped recess that has three holes to take the fittings projecting from the back.Hold the cluster in place while you fix it with a JP04 screw, then repeat the previous steps to fit the other set of lights to the opposite side of the car.Now take the bonnet assembly from Stage 77, the two bonnet retainers, and four JD15 screws.Take the two wires leading from the right-hand lights, and feed them down past the outer rails of the subframe so that they come out underneath.Repeat this on the left-hand side of the engine bay with the left lighting wires.Gently fit the bonnet back over the subframe making sure it is flush with the bodyshell all round.Invert the car, protecting the paint and making sure that the bonnet stays in place. Ensure that all the wires from the previous steps have come out underneath without getting caught up.Take the two bonnet retainers, which are identified by a small ‘L’ for left and ‘R’ for right.Fit the ‘R’ retainer over the two fixing holes on the right hand side of the bonnet underpanel, so that the centre part straddles the front rail of the subframe.Secure the retainer to the bonnet underpanel using two JD15 screws.Repeat this on the left-hand side of the car with the ‘L ’retainer .This forms the hinge on which the bonnet pivots open.
Taking the floor assembly from Stage 95,fit it into the upturned bodyshell, making sure you don’t trap any of the wires coming through the engine bay.Press the floor into place, ensuring that it makes contact at all eight fixing points and then secure the floor using JD01 screw in all these positions.Now take the propshaft, the three sets of lights, and the four tapes provided this time.Fit the round end of the propshaft into the hole in the gearbox, and insert the locating pin into the hole in the floor ensuring you don’t trap any wires. Lay the propshaft in the transmission tunnel and secure the end of the propshaft to the floor with two JP04 screws.Take the rear light LED labelled 08 and fit the plug into the socket labelled 8 on the connection board.Take the rear indicator LEDs labelled 09 and fit the plug into the socket labelled 9 on the connection board.Take the rear light LED labelled 10 and fit the plug into the socket labelled 10 on the connection board.Take the wires labelled 01 - 07and connect them to the corresponding wires coming from the connection board.Note wire 07 has two plugs, connect one to the wire coming from the left-hand side of the bonnet and one to the wire coming from the right-hand side.Take the LED labelled 08, fitted earlier and plug it into the socket in the left rear light (the one nearest the centre of the car).Plug the LED labelled 10,fitted earlier and plug it into the matching light socket on the opposite side.Now take the double LED labelled 09 and plug one LED into the right-hand indicator and the other into the left.Take the two wires leading to the left rear light cluster and lay them neatly between the three pairs of studs under the floor.Peel the backing off one of the strips of tape, and use it to stick the wires in place.Now route the wires diagonally between the next two pairs of studs as shown.Route the right-hand wires around the spare wheel hole, and diagonally between the next two pairs of studs before securing both sets of wires with a single strip of tape.Route the wires along the transmission tunnel, then tape them diagonally across to the engine bay as shown.
Spal attached the following image(s):
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Rank: Super-Elite Groups: Registered
Joined: 19/06/2013 Posts: 4,588 Points: 13,553 Location: West Yorkshire
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Issue 97
Contents: Nose underpanel,Screws
Take the nose underpanel, plus the motif bar from Stage 1, the front bumpers from Issue 96, two JP01 screws and four JP04 screws.Take the motif bar and the right front bumper and position them together, ensuring that the growler motif is the right way up.Fit the ring on the end of the motif bar over the hole in the end of the bumper and screw the parts together with a JP01 screw being careful not to strain the joint.Repeat this step to attach the left front bumper to the motif bar.Align the bumper assembly with the nose underpanel, making sure it is the right way up and the four lugs are positioned over the four mounting holes in the nose underpanel. Secure the bumpers in place with JP04 screws in all four holes.
Now take the main assembly from Stage 96.Match up the two mounting posts under the bonnet with the two lugs on the nose underpanel and press the underpanel firmly into place.
Take the two halves of the fuel tank from Stage 68 and fit the top half of the fuel tank, which has two mounting holes corresponding to the lugs underneath the car. Screw it in place with two JP06 screws and fit the lower half of the tank into position also securing this with two JP06 screws.Now take the assembly of the rear wheels and underside of the car from Stage 81,aligning the assembly carefully with the underside of the car and fitting it carefully into place so that the screw holes line up for the next steps. Use four JP06 screws to fix the edges of the floor pan in the position as shown. Add another JP06 screw just forward of the left rear suspension and also behind the left rear wheel, ahead of the fuel tank. Fit two more JP06 screws to the holes behind the right rear wheel and ahead of the right rear suspension.Use a JD01 screw to secure the undertray behind the left front wheel and also behind the right front wheel.
This issue is now complete. Store the assembly and any unused parts in an issue labelled bag.Spal attached the following image(s):
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Rank: Super-Elite Groups: Registered
Joined: 19/06/2013 Posts: 4,588 Points: 13,553 Location: West Yorkshire
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Issue 98
Contents: Tail underpanel,Plugs
You can test-fit the panel to the car, but it will be safer to keep it in its protective packaging until you fit it permanently.
This issue is now complete. Store the assembly and any unused parts in an issue labelled bag.
Spal attached the following image(s):
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Rank: Super-Elite Groups: Registered
Joined: 19/06/2013 Posts: 4,588 Points: 13,553 Location: West Yorkshire
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Issue 99
Contents: Right rear bumper,Left rear bumper,Rear number plate,Left rear number plate light,Right rear number plate light,Reversing light,Reversing light lens,Tank sump assembly,Spare wheel clamp,Screws.
Take the rear underpanel from Issue 98 and press the light into position,securing the light from the other side with a JP06 screw.Match up the two locating pins on the lens with the holes in the light and press the lens into position.Align the number plate with the recess in the panel noting the offset position of the mounting lugs.Press the number plate into position, securing the plate with two JP06 screws in the mounting lugs. Fit the tank sump assembly, which has a D-shaped lug to match the hole in the body panel,securing it from the other side using a JP06 screw.Take the two rear bumpers, the number plate lights and four JD01 screws.The left number plate light has an L-shaped lug on the back which locks it into its slot beside the number plate. Do not mix up the two lights, as each one will fit only one way around.Making sure that the number plate light stays in place, fit the left rear bumper, aligning the two fixing holes.Secure the bumper with a JD01 screw in both of the fixing holes.Mirror these steps to fit the right hand number plate light and right rear bumper.Take the car assembly, spare wheel, spare wheel clamp, rear underpanel plugs and two JD01 screws. Align the rear underpanel assembly under the rear of the car and screw it into place with a JD01 screw through each of the two holes on the underside.The two plugs supplied with Issue 98 have different lugs on the back which match the shapes of the fixing holes in the rear underpanel. Noting which goes in where, press the plugs into their corresponding holes to conceal the fixing screws.Fit the spare wheel into its recess as shown and taking the spare wheel clamp, press it through the centre of the wheel so it fits as shown.
This issue is now complete. Store the assembly and any unused parts in an issue labelled bag.Spal attached the following image(s):
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Rank: Super-Elite Groups: Registered
Joined: 19/06/2013 Posts: 4,588 Points: 13,553 Location: West Yorkshire
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Issue 100
Contents: Exhaust system, Front header pipe, Rear header pipe, Silencer upper halves, Screws.
Take the exhaust system, silencer halves and two JP02 screws.Align the parts and press them together,securing them with JP02 screws through both holes in the silencers.Fit the exhaust system into the end of the silencer boxes, aligning the mounting plate with the holes in the underside of the car.Secure it with JP02 screws in both mounting holes and secure the rear mounting plate between the silencers with a JD14 screw.Fit the hole in the end of the rear header pipe onto the pin on the rear of the exhaust manifold. Fit the pin on the other end of the rear header pipe into the hole in the fixed pipe.Fit the hole in the end of the front header pipe over the pin on the front of the exhaust manifold and join the other end of the pipe to the second silencer.
Unplug the oil pipe from the side of the sump. This allows you to lift the sump away,unclipping it from the torsion bar frame at the rear and exposing the battery box. Buy three LR44 button-cell batteries. One side is flat and marked with a + sign.Fit the batteries into the box with the + sign facing the spring contact at the front of the car as shown. Refit the sump reconnecting the torsion bar frame and oil pipe in the side.With the car the right way up, fit the cover into the rear and press it right into the recess over the spare wheel.
TESTING THE ELECTRONICS
Open the driver’s door to gain access to the three switches that control your E-type’s lighting effects.
Headlights Move the slider just inside the driver’s door sill to turn on the headlights and rear lights.
Brake lights Press the brake pedal to activate the brake lights.
Hazard warning Push the button on the far right of the dashboard to activate the flashing hazard warning indicators for a short period.
This brings to a close the build of the Jaguar E-Type model.Spal attached the following image(s):
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