The Kougar Resto Thread
Discussion
Loads of you were loving the Kougar when it appeared in my garage earlier this year. Well, about 3 weeks ago I put it in the workshop to start the resto / recommission. A tale of repairing many 'orrible old bodges as usual for something like this.
A bit of Automotive Porn first - the overhauled Webers.
Again Coopercraft front callipers and discs
New rear brakes - stock SII XJ6
Coming apart
Paint stripped off the chassis as far as poss by Lesley
New lower steering column made with nice 3/4" rose joint
Upper steering column shortened and new brackets made
Floor altered to take new pedal box. Old pedals remove - they were sort of top hinged...
Interesting one. A plate to go on the bulkhead for the upper steering column / shaft to go through. I made the alloy bush to hold an oil seal to act as a seal around the shaft, so no draughts or nasty smells! The seal is actually a Harley starter seal - it had the correct I/d, so the rest was easy.
Back end out for refurb
Highly intelligent (not) way of making rubbish roll over bar fit! Now repaired.
Stupid roll bar (see above) mount.
Cut the SOB'S off!
Cage removed
Painting...
More painting...
And even more painting!
Rear end going back together
...and almost ready to fit
Whizzey new starter, now fitted
Ceramic coated manifolds
Re chromed grille
Electronic sparky thing
New front brakes fitted (plus new wheel bearings) and new braided brake lines made and fitted
That will do for the mo'.
Not too bad for 3 weeks or so's work. Not quite Gas Monkey - but there's only one of me! Amazing how much time you spend fettling. Grind bits of the diff away to get the new callipers to fit etc..
So if/when I go to the Palace to meet Brenda, and she asks "Eend whart dew yew dew?" My reply will be that I used to be an engineer, now I'm a fettler m'aam!
Next on the list is to finish the brake pipes and pedal box. Make a cradle for the new petrol tank and fit the rear end. Waiting for new shox and springs. Fit waterpump, distributor, manifolds, cam covers, alternator conversion with serpentine kit, finish chassis paint, fit new fuse boxes and so on.
Poss be running by next weekend.
A bit of Automotive Porn first - the overhauled Webers.
Again Coopercraft front callipers and discs
New rear brakes - stock SII XJ6
Coming apart
Paint stripped off the chassis as far as poss by Lesley
New lower steering column made with nice 3/4" rose joint
Upper steering column shortened and new brackets made
Floor altered to take new pedal box. Old pedals remove - they were sort of top hinged...
Interesting one. A plate to go on the bulkhead for the upper steering column / shaft to go through. I made the alloy bush to hold an oil seal to act as a seal around the shaft, so no draughts or nasty smells! The seal is actually a Harley starter seal - it had the correct I/d, so the rest was easy.
Back end out for refurb
Highly intelligent (not) way of making rubbish roll over bar fit! Now repaired.
Stupid roll bar (see above) mount.
Cut the SOB'S off!
Cage removed
Painting...
More painting...
And even more painting!
Rear end going back together
...and almost ready to fit
Whizzey new starter, now fitted
Ceramic coated manifolds
Re chromed grille
Electronic sparky thing
New front brakes fitted (plus new wheel bearings) and new braided brake lines made and fitted
That will do for the mo'.
Not too bad for 3 weeks or so's work. Not quite Gas Monkey - but there's only one of me! Amazing how much time you spend fettling. Grind bits of the diff away to get the new callipers to fit etc..
So if/when I go to the Palace to meet Brenda, and she asks "Eend whart dew yew dew?" My reply will be that I used to be an engineer, now I'm a fettler m'aam!
Next on the list is to finish the brake pipes and pedal box. Make a cradle for the new petrol tank and fit the rear end. Waiting for new shox and springs. Fit waterpump, distributor, manifolds, cam covers, alternator conversion with serpentine kit, finish chassis paint, fit new fuse boxes and so on.
Poss be running by next weekend.
Blimey, can't believe it's been a month. Anyway, had a break from this to sort out the Widget for a couple of weeks.
Anyway, latest stuff.
New ribbed pullies and belt. New alternator and modded bracket for the alternator. Made a nice adjuster - works much better than a slidey thing! Note new cross member for the new radiator.
New alloy rad , fresh from China. Ordered on Christmas Eve, here on Thursday!!
Chinese oil catch tank. £39 delivered. They would like me to be the UK agent. Could be worth a go!
New 123 distributor installed with new leads etc. Bung made for unused port on pump
XJ6 S2 oil filter mount to give a spin on conversion. The oil cooler will need a new sandwich plate, but that can wait for now.
The thermostat housing didn't have a recess for the 'stat - probably never had one fitted. So here cutting the recess.
Likely firing it up tomorrow!!
Anyway, latest stuff.
New ribbed pullies and belt. New alternator and modded bracket for the alternator. Made a nice adjuster - works much better than a slidey thing! Note new cross member for the new radiator.
New alloy rad , fresh from China. Ordered on Christmas Eve, here on Thursday!!
Chinese oil catch tank. £39 delivered. They would like me to be the UK agent. Could be worth a go!
New 123 distributor installed with new leads etc. Bung made for unused port on pump
XJ6 S2 oil filter mount to give a spin on conversion. The oil cooler will need a new sandwich plate, but that can wait for now.
The thermostat housing didn't have a recess for the 'stat - probably never had one fitted. So here cutting the recess.
Likely firing it up tomorrow!!
Engine now running! OOOh sounds good!
Looking good!
Alloy rad, huge cooling fan and catch tank.
Rear end in. Now fitting new foam filled tank. The tank needs altering a bit, plus notching the chassis a bit.
Now need to organise new wheels and tyres. Plus shox and springs. I've decided to rip out all the old wiring as there is so much of it that isn't needed as it came from the donor car. Then I'll make a new loom with some nice led fuse boxes etc. The painter came to day to price up the paint - I have about 2 weeks to finish, including all the fibreglass work ready for him to paint.
Seats here on Thursday and off to the manufacturers to get new transmission tunnel and have a look at the chassis mods he has done....
Looking good!
Alloy rad, huge cooling fan and catch tank.
Rear end in. Now fitting new foam filled tank. The tank needs altering a bit, plus notching the chassis a bit.
Now need to organise new wheels and tyres. Plus shox and springs. I've decided to rip out all the old wiring as there is so much of it that isn't needed as it came from the donor car. Then I'll make a new loom with some nice led fuse boxes etc. The painter came to day to price up the paint - I have about 2 weeks to finish, including all the fibreglass work ready for him to paint.
Seats here on Thursday and off to the manufacturers to get new transmission tunnel and have a look at the chassis mods he has done....
1000th post!!
Anyway. After a pleasant time with Simon, the present manufacturer of Kougar, I decided to do some more drastic stuff. There is a crossmember which you catch your toes on, and is a real pain. So out it came, ready for a higher, slimline replacement.
Alloy petrol tank chopped around ready for welding.
Made a start on the brackets to support the tank. Should get those done tomorrow.
Interior well and truly stripped out. All the cruddy wiring now out, Dashboard out so I can make a new one using the old instruments and new switches.
Some rather nice Ritchfield seats - another Ebay bargain!
Damn, forgot to flip that pic......
Had a message from the original builder through Ebay. Don't really want to tell him what a really bad job he did!
Anyway. After a pleasant time with Simon, the present manufacturer of Kougar, I decided to do some more drastic stuff. There is a crossmember which you catch your toes on, and is a real pain. So out it came, ready for a higher, slimline replacement.
Alloy petrol tank chopped around ready for welding.
Made a start on the brackets to support the tank. Should get those done tomorrow.
Interior well and truly stripped out. All the cruddy wiring now out, Dashboard out so I can make a new one using the old instruments and new switches.
Some rather nice Ritchfield seats - another Ebay bargain!
Damn, forgot to flip that pic......
Had a message from the original builder through Ebay. Don't really want to tell him what a really bad job he did!
Onwards and upwards......
Tank back from welding.
Look carefully and you can see the foam. (Removed before welding!!!)
Odd thing is, how the floor is open to the elements. So supports made and fitted for floor extensions.
Tank supports made and fitted. Had to chop a little out of the top rail.
Made some ally bulkhead panels to also close of the cockpit.
Because I am using conventional seats rather than the old hammock ones, the seats need a bit of tweaking - a bit more upright and a bit shorter, so that they fit properly. Welding and stuff here..
New air stapler, nasty glue stuff...
Finished article now fits just right. Still have passenger one to do, but that can be done while the painting is done.
This weekend will hopefully see the fibreglassing done. Need to get some rubber strip to mount the tank = the 10mm I have is too thick. Weld up the member over the tank, finish welding the floor extensions.
Tank back from welding.
Look carefully and you can see the foam. (Removed before welding!!!)
Odd thing is, how the floor is open to the elements. So supports made and fitted for floor extensions.
Tank supports made and fitted. Had to chop a little out of the top rail.
Made some ally bulkhead panels to also close of the cockpit.
Because I am using conventional seats rather than the old hammock ones, the seats need a bit of tweaking - a bit more upright and a bit shorter, so that they fit properly. Welding and stuff here..
New air stapler, nasty glue stuff...
Finished article now fits just right. Still have passenger one to do, but that can be done while the painting is done.
This weekend will hopefully see the fibreglassing done. Need to get some rubber strip to mount the tank = the 10mm I have is too thick. Weld up the member over the tank, finish welding the floor extensions.
Jeez, can't believe it has been 6 months since I posted any more on the Kougar!
Anyway, it is coming back from painting tomorrow, so I can crack on.
Here are some update pics meanwhile.....
Welding of back end done.
Bootlid cut out and landing made and fitted. Bit of a bugger to get it all in line - but worth it so there will be some accessible luggage space.
Bootlid fitted, holes from roll bar filled and all other holes and remainders of various adventures filled. Used gel coat filler as this is much better for this than normal filler
Fibreglass work filling old petrol filler hole etc.
Usual mess from WIP.
Petrol tank after a bit of alteration and welding - plus you can see the foam.
Trying to repair the clock!
The car is actually running now. I have the new wheels too. More pics v.soon.
Anyway, it is coming back from painting tomorrow, so I can crack on.
Here are some update pics meanwhile.....
Welding of back end done.
Bootlid cut out and landing made and fitted. Bit of a bugger to get it all in line - but worth it so there will be some accessible luggage space.
Bootlid fitted, holes from roll bar filled and all other holes and remainders of various adventures filled. Used gel coat filler as this is much better for this than normal filler
Fibreglass work filling old petrol filler hole etc.
Usual mess from WIP.
Petrol tank after a bit of alteration and welding - plus you can see the foam.
Trying to repair the clock!
The car is actually running now. I have the new wheels too. More pics v.soon.
Back from painting today.
Nice and shiny in OEW.
Pity that everything is covered in overspray. So the whole thing has to come apart again to have the alloy bits re polished, the chassis repainted, and the exhaust, I guess, will have to gop back to Zircotec to be re done. That alone could cost £600. Not very happy as this has set the job back at least 3 weeks.
why is it that painters do this? I used to do bodywork 30 years ago and never had this problem. Bums.
Nice and shiny in OEW.
Pity that everything is covered in overspray. So the whole thing has to come apart again to have the alloy bits re polished, the chassis repainted, and the exhaust, I guess, will have to gop back to Zircotec to be re done. That alone could cost £600. Not very happy as this has set the job back at least 3 weeks.
why is it that painters do this? I used to do bodywork 30 years ago and never had this problem. Bums.
More progress.
Had to strip the whole car to a bare shell because of all the overspray!
Managed a couple of extra jobs as a result.
Interior resprayed.
Handbrake installed and working!
Rear end in after a repaint.
Pedal box moved and throttle pedal sculpted a bit to give more clearance.
Lots more to go. Brakes to bleed and get the engine back in.
Had to strip the whole car to a bare shell because of all the overspray!
Managed a couple of extra jobs as a result.
Interior resprayed.
Handbrake installed and working!
Rear end in after a repaint.
Pedal box moved and throttle pedal sculpted a bit to give more clearance.
Lots more to go. Brakes to bleed and get the engine back in.
Thread revival again!
Been so busy that I havent had a chance to do all the fiddly jobs.
Now just about done. Had a r/road session, but still needed fettling.
There are always so many bits to fettle on a job like this. Leaky hose, the carb setting up, handbrake cable breaking, fitting mirrors, rear lights sorted, final odd bits of paint on the suspension etc, setting up the angle of dangle, etc etc.
A few pics from Brooklands
Note the genuine Spitfire starter button! The red knob is the ign on/off button as it is keyless - just use the immobiliser thang. Led lights, etc. Machined turned dash - my first attempt!
It is fun to drive, pulls so well. About 240bhp and the same torque figure. Jaguar were a little optimistic with their figures - a stock 3.8 is usually around 130/150 bhp.
Electronic ignition, lightweight starter, alloy rad (Chinese Ebay of course!), very modified interior with proper seats - unlike the original design.
Now up for sale!
Been so busy that I havent had a chance to do all the fiddly jobs.
Now just about done. Had a r/road session, but still needed fettling.
There are always so many bits to fettle on a job like this. Leaky hose, the carb setting up, handbrake cable breaking, fitting mirrors, rear lights sorted, final odd bits of paint on the suspension etc, setting up the angle of dangle, etc etc.
A few pics from Brooklands
Note the genuine Spitfire starter button! The red knob is the ign on/off button as it is keyless - just use the immobiliser thang. Led lights, etc. Machined turned dash - my first attempt!
It is fun to drive, pulls so well. About 240bhp and the same torque figure. Jaguar were a little optimistic with their figures - a stock 3.8 is usually around 130/150 bhp.
Electronic ignition, lightweight starter, alloy rad (Chinese Ebay of course!), very modified interior with proper seats - unlike the original design.
Now up for sale!
Edited by V8 FOU on Monday 25th July 23:26
Edited by V8 FOU on Tuesday 26th July 22:06
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