XJ6R – Bulkhead hole

XJ6R Hole cut out

To get the ECU loom from the engine bay into the passenger foot well I needed to make the LHD steering column hole larger. This hole is used to feed the engine vacuum to the AC unit to drive the various flaps and valves.

Vacuum pipes
Vacuum pipe panel
Strengthening ring (after cut out)
Strengthening ring (after cut out)

There is a thick strengthening ring surrounding the standard hole so I decided to cut around that meaning the hole would be around 60mm in diameter. The plugs on the loom would not fit through the standard hole as they are quite bulky.

ECU Plugs
ECU Plugs
Wooden template
Wooden template notice the bulkhead cutout below it for the other required connections

I had to make up a simple wooden template to enable me to centre a holesaw in the right place. The holesaw, along with some cutting fluid made short work of the sheet metal and I was left with a nice clean cutout. Picture taken after a quick clean up and a bit of paint for protection.

Hole cut out
Hole cut out

I will be using the rubber gaiter/plug to seal up the hole as used on the original XJR.

Gaiter on loom
Gaiter on loom

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