As you know I have been working on the tweeter mounts and they are pretty much done. Also the vents on the inside of the boot, left and right as mine are damaged.

I checked my quarter glass brackets and found that both were broken. I cleaned the joint and bonded it back together. I then spent some time measuring it and modelling it in SOLIDWORKS. I have printed a basic replica bracket just to check things out of ultra tough filament. It looks good and fits. The next step is to improve it by beefing it up and fitting two M5 brass flanged presserts.

The presserts will be here in a few days and the beefed up version will be printed ready. If all is good I will print some out of carbon fibre hyper pla.

 

It looks good. I love to see creativity.
One of mine was broken in the same way. I cut, filed and tapped a replacement from a bit of scrap aluminium. A few hours work with hand tools and I didn't bother with the webs and kept it simple.
I think your way's the future if printing can make it strong enough.
I recall there being enough space for the breaking point to be thicker.
Just an idea: maybe coarse self tapping screws will work in your material rather than thread inserts.
Best wishes

 

The thing with self-tappers is that they force the hole material out which creates a lot of pressure on the hole to expand. Not ideal.

 

The threaded presserts bite into the CF part when the bolt goes in, this serrated edge stops it from rotating or coming out.

I have got the Carbon Fibre filament in and it is really good, I have already printed out a replacement bracket part for one of my headlights as it has had an old previous repair that was not upto the task.

Measured things up from the other headlight tab and added an inner brace to help reinforcei t a bit more with a small back fillet, bonded into place using JB Weld Plastic Bonder. Once its all dry it will also have some locking pins in place.

 

Heh heh. Your Jaguar is a Ford, too!

 

I finally got round to getting the flanged M5 threaded inserts. I have fitted them into the test bracket, they have a good interference fit. The bolts also have an interference fit due to the clamping from the insert compression against the walls of the bracket holes.

I will do a test fit today and see how it looks, if everything is ok I will print out some carbon fibre reinforced brackets and fit. If they are good then that wraps this up and I can print a load off.

The M5 insert has a serrated outer that bites into the bracket preventing it from rotating.




As you can see the bracket has a lot more mass to it with a 100% solid body. I have pushed and pulled on the bracket and it does not flex or warp. Hopefully this solves the issue for many owners with the broken bracket issue.

 

Brilliant!! This's quite a common problem. Both mine broke some time ago but replacement windows were cheap then and I just bought new ones.

 

Is this a coupe thing or convertibles as well?

 

Just the coupe I think, don't the rear quarters go down on the convertible?

 

Correct.

 

The rear side windows are synch'd to the convertible top operation unless you install the aftermarket remote control top module with optional side window controller that was invented by Forum Member WhiteXKR, a.k.a. Steve, the Jag Wrangler. That device allows independent operation of both rear side windows at the same time regardless of the position of the top. Many happy customers here! Search this Forum.
https://www.thejagwrangler.com/

 

That is my second install after Mr12Volt.
Gotta have my CarPlay.

 

isn't the MR12Volt only for the later xk150s?
wj

 

any thoughts on the 'strap' that also gets damaged when the headlight gets pushed?
wj

 

Really pleased to let you know that the bracket did fit first time. First attached to the glass bracket and then slid back into place and then the bolt through the body to the bracket and it all tightened down fine. I swapped the bolts around, using the longer one on the glass bracket and the shorter through the body to the bracket. This was because the thread for the top is a little further back now because of the thicker build. I am going to run some carbon fibre reinforced ones today and will fit them tomorrow.

Very happy these worked ok.

 

Excellent work there buck.

 

Two sets of carbon fibre strand reinforced brackets. I just have to run an M5 bolt through them to open the inserts up ready for fitting. Will fit a set tomorrow.

 

Nicee, would be great to sell these

 

Hopefully yes, I am thinking of a set of 4 a time along with the tweeter rings and a couple of other things. But I have to be careful as they are based off Jaguar parts and I want to make sure there is no legal issue.

I have the contact details for Jag classic division so I will be writing to them.

 

I'm in for left side, but I'll spring for a pair whenever you're ready.