[xj] Series I (& II) Fresh Air Ducts

LIST:

Since I brought Old Red home I really have not liked how the
drivers door fit, it was just not right. Did a search of the
archives for ‘‘door adjustment’’ and drbill (Bill Cooper) was
the only person that showed up. I sent Bill a private email
asking for advice and promptly received a helpful procedure
from him. I proceeded with the adjustment and after some
fiddling around I got it pretty damn good. In fact, I was so
pleased I went ahead and adjusted the other 3 just for good
measure. Very pleased with the finished product.

ANYWHO, during the process of adjusting the front doors I
had to remove a couple of false panels in the wheel wells
and discovered why my foot well fresh air vents had
virtually no air from them. The answer was, ‘‘DRUM ROLL
PLEASE’’, no ducts from the opening above the headlight to
the flange in the unibody sheet metal. Another reason why I
am beginning to really dislike the previous owner!

Off to town to confront the pimply faced kid behind the
chain auto parts counter for some 2’’ air ducting that was at
least 4’-5’ long. This is akin to talking to the wall
especially when you throw in that it is going into a '73
Jaguar XJ6. Unfortunately, our best and brightest go away to
school only to never return. We are then forced to deal with
the rest.

Enough bitchin, any ideas on where to get bulk 2’’ air
ducting for this application. The old standby spiral wound
vinyl/cloth air duct WILL NOT do the job. It’s ID is just a
bit too small. There were a few remnants left on one side
and it’s composition is just like the 2’’ expandable quasi
metal carburetor preheat hose you can readily buy in short
(18’’) lengths. The ID on that preheat hose is a bit bigger
than the spiral wound stuff and fits on the flanges in the
car perfectly.

To do the job I would need this 2’’ carburetor preheat hose
to be at least 5’ long instead of the readily available 18’’
lengths. I could probably figure out some Rube Goldberg
system using the short sections of hose and some thin wall
ABS tubing but I would rather not.

Any input really appreciated!!!–
Gordon S. Tompkins ('73 XJ6, '85 XJ6 & '03 S-Type)
Springville, CA, United States
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In reply to a message from GSTompkins sent Wed 15 Jun 2011:

McMaster-Carr in Chicago has an online catalog which has just about
anything thing you can think of in hardware.

Surely they’ll have the right ducting.

When I was still at the university, I was ordering something from
them almost every day of the week.–
Denny, 71 XJ6
Benbrook, Texas, United States
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In reply to a message from GSTompkins sent Wed 15 Jun 2011:

Hi Gordon,
Try Vintage Air. That is the same outfit that sells the electric
heater valve that is a nice replacement for the often failed vacuum
heater switch found on the S1.
Dave Harlan
Mill Valley, CA
72 XJ6
03 S-Type
08 F250 w/Camper–
The original message included these comments:

To do the job I would need this 2’’ carburetor preheat hose
to be at least 5’ long instead of the readily available 18’’
lengths. I could probably figure out some Rube Goldberg
system using the short sections of hose and some thin wall
ABS tubing but I would rather not.
Any input really appreciated!!!


David Harlan
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In reply to a message from David Harlan sent Wed 15 Jun 2011:

David,

I did contact Vintage Air via email. Got a response from a
sales rep that had a quote for their 2’’ spiral wound duct at
$105.00 per foot.

JUST A BIT OUTSIDE OF MY PRICE RANGE!!!

I had indicated in my original post that the Gates 2’’ spiral
wound air duct is too small on the ID so I assume theirs is
the same. As I also indicated in my original post I found
remnants of what I think was the original ducting. It is
dimensionally the same and made of the same aluminum
telescoping material as carburetor preheat hose commonly
sold in 18’’ length in auto parts stores. Now I need to find
a supplier of that same hose/duct in 4-5 foot lengths.–
The original message included these comments:

Try Vintage Air. That is the same outfit that sells the electric
heater valve that is a nice replacement for the often failed vacuum
heater switch found on the S1.


Gordon S. Tompkins ('73 XJ6, '85 XJ6 & '03 S-Type)
Springville, CA, United States
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G’day Gordon,
Strangely enough, this air ducting was still fitted to
SIII cars even after the footwell vents were deleted. I’d almost say you
could source some from a direlect SIII, but the ducting is not good
quality and falls apart when disturbed. Have you thought of using
corrugated light duty flexible electrical conduit? That may be cheaper
and easier to find. You wouldn’t want to spend too much money on this,
there won’t be much air flow from these ducts anyway.

John Hudson
Brisbane Australia
85 XJ6
95 X300 Sovereign 4.0On 16/06/2011 2:58 AM, GSTompkins wrote:

LIST:

ANYWHO, during the process of adjusting the front doors I
had to remove a couple of false panels in the wheel wells
and discovered why my foot well fresh air vents had
virtually no air from them. The answer was, ‘‘DRUM ROLL
PLEASE’’, no ducts from the opening above the headlight to
the flange in the unibody sheet metal.

Any input really appreciated!!!

Gordon S. Tompkins ('73 XJ6, '85 XJ6& '03 S-Type)
Springville, CA, United States

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In reply to a message from John Hudson sent Thu 16 Jun 2011:

Hi Gordon, I’ve had mine out - some years back now - they are
definitely the originals and if my memory serves correctly, they
are plastic.

I run a wood working business, and reckon 2’’ dust extractor hose
could be the go. We can get a good quality one made from a type of
PU with a high tensile steel reinforcement in it. It’s quite
flexible but will never crush at around $16 per metre, or there’s a
PVC type with a nylon reinforcement - not as flexible but is around
$10 per metre. (I’m talking USD). I’d try a woodworking tools
supply company. I’d expect it to be cheaper still in your market.–
Neville S1 XJ12, Megasquirt ECU
Christchurch, New Zealand
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In reply to a message from Nev.W sent Thu 16 Jun 2011:

Just out of curiosity, is there some reason you don’t source
these from a parts car, like one of David Boger’s? They
don’t wear out, and are probably seldom removed unless one
removes the wing.–
The original message included these comments:

I run a wood working business, and reckon 2’’ dust extractor hose
could be the go. We can get a good quality one made from a type of


Bob Wilkinson, 73 XJ6
Saint Louis, MO, United States
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In reply to a message from Robert Wilkinson sent Thu 16 Jun 2011:

I dunno, Robert. All this talk about air ducting, the ones
David has will suddenly become family heirlooms! ;>))–
The original message included these comments:

Just out of curiosity, is there some reason you don’t source
these from a parts car, like one of David Boger’s? They
don’t wear out, and are probably seldom removed unless one
removes the wing.


Bill Cooper, S-3 VDP 5spd, XJ12-C (2), XJ6-C, S-1 XJ12 (2)
Charlotte, NC, United States
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In reply to a message from Robert Wilkinson sent Thu 16 Jun 2011:

Robert, Neville & John:

Never thought of a Series III let alone David Boger. I
should send him an email and see what he has.

If the remnants I found are the original I might disagree
about them wearing out. The pieces that I did find readily
fell apart with just the slightest pressure or movement. I
did find a humongous mouse nest in the area above the RH top
false panel in the wheel well. It was made up of all sorts
of materials including the air ducts. By the way, the LH
side had been totally removed by the PO and blocked off by
duct tape.

Actually, I do have a Rube Goldberg arrangement in mind. The
straight sections of the duct can be made from 2’’ thin wall
ABS irrigation piping found at most home improvement stores.
The front & rear hook up to the car flanges plus the bend
between the 2 straight sections can be fashioned from the 2’’
aluminum carburetor (18’’ length) preheat duct. This would
all held in place by the 3 hose clamps already attached to
the top false panels. Can do that for a bit less than
$105.00 a foot.

It would just be a lot cleaner if I could find a suitable
length of proper sized ducting. To fit the car flanges the
duct would have to have a 2’’ ID. All the spiral wound
ducting I have found so far has an ID just a bit less than
2’’ and will not go onto the flanges in the car. That preheat
hose just slips right on.–
The original message included these comments:

Just out of curiosity, is there some reason you don’t source
these from a parts car, like one of David Boger’s? They
don’t wear out, and are probably seldom removed unless one
removes the wing.


Gordon S. Tompkins ('73 XJ6, '85 XJ6 & '03 S-Type)
Springville, CA, United States
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In reply to a message from GSTompkins sent Thu 16 Jun 2011:

Have you thought about the old flex pipe for exhaust? I’ve seen
that in some parts store. Still pretty cheap.

As for someone commenting that there isn’t much air flow through
them, my 71 has very good flow thought the vents.–
Denny, 71 XJ6
Benbrook, Texas, United States
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In reply to a message from jagwagon sent Thu 16 Jun 2011:

Gordon when you get the ducting sorted out, also have a look at the
inside where the round plastic vent is. It’s secured with a
phillips head screw through the centre. When I removed mine on the
passenger side I found that upon assembly, there had been no hole
cut in the carpet covered trim panel under the vent. Putting the
Hole in (removing the hole?) helped the airflow some.–
Neville S1 XJ12, Megasquirt ECU
Christchurch, New Zealand
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As someone else suggested earlier, you need to go to McMaster.com

If you click on 2" ID there are literally a dozen types and styles to choose from, including the corrugated aluminum you are looking for.

-GaryOn Jun 16, 2011, at 7:14 PM, GSTompkins wrote:

In reply to a message from Robert Wilkinson sent Thu 16 Jun 2011:

Robert, Neville & John:

Never thought of a Series III let alone David Boger. I
should send him an email and see what he has.

If the remnants I found are the original I might disagree
about them wearing out. The pieces that I did find readily
fell apart with just the slightest pressure or movement. I
did find a humongous mouse nest in the area above the RH top
false panel in the wheel well. It was made up of all sorts
of materials including the air ducts. By the way, the LH
side had been totally removed by the PO and blocked off by
duct tape.

Actually, I do have a Rube Goldberg arrangement in mind. The
straight sections of the duct can be made from 2’’ thin wall
ABS irrigation piping found at most home improvement stores.
The front & rear hook up to the car flanges plus the bend
between the 2 straight sections can be fashioned from the 2’’
aluminum carburetor (18’’ length) preheat duct. This would
all held in place by the 3 hose clamps already attached to
the top false panels. Can do that for a bit less than
$105.00 a foot.

It would just be a lot cleaner if I could find a suitable
length of proper sized ducting. To fit the car flanges the
duct would have to have a 2’’ ID. All the spiral wound
ducting I have found so far has an ID just a bit less than
2’’ and will not go onto the flanges in the car. That preheat
hose just slips right on.

The original message included these comments:

Just out of curiosity, is there some reason you don’t source
these from a parts car, like one of David Boger’s? They
don’t wear out, and are probably seldom removed unless one
removes the wing.


Gordon S. Tompkins ('73 XJ6, '85 XJ6 & '03 S-Type)
Springville, CA, United States
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In reply to a message from Gary Evans sent Thu 16 Jun 2011:

Gary,

This clearly proves how dense I can be at times. After the
first post about this company I looked them up. I searched
for tubing and came up with nothing close so I figured that
was a waste of time. Never thought to search for duct or
ducting. I should take the blinkers off some times!!!

I think I will email these people and ask if the ID is
really 2’’ not just a bit less. Would hate to spend 50-60
bucks and find that it is also too small.–
The original message included these comments:

As someone else suggested earlier, you need to go to McMaster.com
McMaster-Carr
If you click on 2’’ ID there are literally a dozen types and styles to choose from, including the corrugated aluminum you are looking for.


Gordon S. Tompkins ('73 XJ6, '85 XJ6 & '03 S-Type)
Springville, CA, United States
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In reply to a message from GSTompkins sent Thu 16 Jun 2011:

Funny, I sold a set of this ducting this AM to the aluminum
recycler for $0.45 per pound… Figure I made at least $0.30 for
the set…

David
EverydayXJ.com–
84 XJ6 (Driver) 86 XJ6 (Project) Parts cars piling up.
Rockwell, NC, United States
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In reply to a message from DavidBoger sent Mon 20 Jun 2011:

David & List:

I have been on an extended trip away from home for family
pleasure/business purposes. This required that I suspend my
work on Old Red since the 14th of June. This includes the
work on the fresh air ducts. Old Red sits forlornly on jack
stands with the front wheels off, the false wheel well
panels on the floor awaiting my return.

This is the obvious reason I haven’t contacted you or
anybody else for parts. I have decided to go ahead with my
Rube Goldberg solution when I am able to get back home.
Perhaps I am too cheap (frugal is the word I prefer) but
even the $60-$70 bucks for the McMaster-Carr ducting is
simply too much. I can build an entirely satisfactory system
for less than $20 bucks. I do admit some of this is because
I have some of the ‘‘stuff’’ already on hand in my shop.

You talk about funny, I have a brand new Burla straight
through muffler (plus a couple of others) in that same shop
I can’t even give away in a town that has tons of old
‘‘Detroit Iron’’ running around in it. It looks like it will
be sold as scrap as well. I can assure you that it will not
be in NOS condition when the scrap dealer weighs it.–
The original message included these comments:

Funny, I sold a set of this ducting this AM to the aluminum
recycler for $0.45 per pound… Figure I made at least $0.30 for
the set…


Gordon S. Tompkins ('73 XJ6, '85 XJ6 & '03 S-Type)
Springville, CA, United States
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