Adding a Reverse Gear “Back-up” Light

I use a Toyota 5-speed gearbox in the Bloody Beast, but I have never taken advantage of the “back-up” light switch feature that is available on the transmission. Our Healeys did not have a “back-up” light. Steve Gerow discovered a LED light made for the job designed to be mounted on the lower holes of the license plate. So, thanks to you Steve! I have borrowed another one of your ideas. I could have used a number plate lamp from a Jaguar that incorporates a reverse light, but while period correct, the light would not have been nearly as bright and therefore noticeable, and that is the whole point.

LED “Back-up” Light

I visited my local Toyota dealer to see if I could locate a pigtail and plug for the reverse switch terminal located on the LH side of the gearbox, but had no luck there. I found some very small wiring terminal connectors on the internet and made up my own wires to fit the small spade connectors at the switch.

Wire Terminals for Toyota gearbox reverse switch

 

Wiring attached to the Toyota gearbox reverse switch

Wiring leads from Reverse Switch

The forward wire needs a switched power source and I decided to use the fused wire from the ignition switch to the cruise control conveniently located on the RH side of the gearbox. I simply used a four way bullet connector to “splice-in” in the grey wire to the reverse switch. I will never be using the cruise control while in reverse gear so no load issues, although the load requirement of the LED light strip is miniscule anyway.

Four Way Bullet Connector for switched power source

I used an 18 gauge green wire with an orange tracer (sourced from British Wiring) for the wiring from the grey lead to the LED light at the rear of the car. A disadvantage of adding electrical items post-restoration is that is not easy to add the necessary wiring without it being visually obvious. In this case it is either under the car or in the boot hidden by the armacord lining so not too bad.

Wiring Along Frame Rail

Up and over the Fuel Pump and Through the Boot Bulkhead

Wiring Through the Boot Bulkhead and under Armacord and out the Shroud Number Plate Wiring Grommet

The LED light red wire was connected to the green/orange wire for +12 volts and its black ground wire was connected by a self-tapping screw into the rear frame.

LED Reverse Light

Assorted Electrical Modifications

The Original Electrical System

 The electricals were a 12 volt positive ground Lucas system. The battery with an interrupt switch was located in the boot. The system consisted of the following: Fuel pump: SU AUA72 Voltage Regulator: Lucas Type 106/2 Single Fuse Box: Lucas Type FS6 with 50 and 35 amp fuses Electric Overdrive: Laycock de Normanville Two horns: Lucas Type HF1748 Dynamo: Lucas No. 22530 A or B

Modified Electrical System

Battery

I decided to go with a modern battery and replaced the original style with an Optima gel battery. Part Number: 34 (8002-002) RedTop®; Battery; Group 34; Cold Crank Amps 800; Crank Amps 1000; Reserve Capacity 110; Ampere Hour 50; Top Terminal; L-10 in.; W-6 7/8 in.; H-7 13/16 in.; UNBOXED.

Optima Battery

Optima Battery

Battery Master Switch

Numerous owners have reported failures with the original Lucas voltage interruption switch located in the boot. While these switches can be renewed, I decided to replace mine with a modern equivalent, sourced from Pegusus Racing.

Battery Master Switch

Battery Master Switch

Negative Ground and Alternator

I made many “personalizations” in the Bloody Beast that required modifications to the electrical system. To accommodate these changes, conversion to negative ground and exchanging an alternator for the original dynamo or generator were in order. Alternator Conversion Big HealeyAlternator conversion wiring instructions.

Conversion to Negative Ground

Conversion to Negative Ground

Alternator Mount Kit

Alternator Mount Kit

Delco Alternator

Delco Alternator

Supplementary Fuse Panel

To support the additional electronic functions I would be adding to my BT7 I thought it might prove helpful to add a supplementary fuse panel. The original electrical system was “under-engineered” when it came to protecting the electrical components and wiring. The unit I added was a “Painless” brand, available at most auto parts stores. It utilizes modern blade fuses. ACCY 1 Yellow Ignition Hot – Two speed heater; ACCY 2 Blue Ignition Hot – Amplifier; ACCY 3 Purple Constant Hot – Accessory power (cigar lighter) and the windscreen washer via a red wire. I mounted the panel below the dash fascia on the firewall interior. Accessory Fuse Block

Extra Fuse Block

Extra Fuse Block

Gear Reduction Starter

In the engine bay, in addition to replacing the dynamo with a modern alternator, I opted to go with a gear reduction starter. It is a little difficult to see in the image below. It is to the left of the oil filter. These are the installation instructions that came with the starter: Gear Reduction Starter.

Gear Reduction Starter

Gear Reduction Starter

Fuel Gauge Dampener

Healey owners know that the fuel gauge needle tend to bounce around making it difficult to get an accurate read on fuel level. Steve Gerow found an answer. A small device ordered from Zim’s Autotechnik, http://www.allzim.com/acatalog/Fuel_Gauge_Stabilizer.html a Porsche parts vendor, helps to steady down that needle, minimizing but not eliminating fluctuations. Thanks, Steve!

Fuel Gauge Stabilizer

Fuel Gauge Stabilizer

Remote Control Courtesy Lamps in Interior and Boot

I wanted to install courtesy lamps in the interior footwells and in the boot. However, I did not want to drill holes in the doors for typical courtesy lamp operation, so I decided to modify a remote security key fob to actuate my system. Upon clicking a button on the fob, the floor and boot lamps illuminate for 40 seconds and then extinguish. I also installed a toggle switch on a panel under the dash that permits continuous power to the lamps until switched off. To look “period,” the lamp I used in the boot is actually an original-type Lucas license plate lamp with the chrome metal shroud removed. The system works quite nicely. At night when I approach the car, I can simply hit the key fob button and Viola, I have interior lights!

Courtesy Light Wiring

Courtesy Light Wiring

RH Footwell Courtesy Lamp

LH Footwell Courtesy Lamp

Boot Lamp

Lucas SLR-570 -5″ Driving Lights

I like the looks of the 5″ driving light, while others will certainly prefer the 7″ option. I mounted mine with a combination tie down hook and lamp bracket sourced from Cape International. Wiring guidance was proved by an excellent article written by John Trifari. Details of the installation are provided in the restoration blog.

Lucas Driving Lights

Lucas Driving Lights

Rear Reflector Conversion to Halogen Lamps

Other Healey drivers recognizing that we have very little illumination in the rear of our cars discovered a neat conversion of the rear reflectors to additional lamps. I modified mine for the safety improvement. I don’t recall the source, but this is a “how to” article on the conversion as I did it. Reflector conversion. A more recent conversion using LED lights is referenced here: Conversion of Reflector to LED Again, details in the restoration blog.

Rear Modified Reflectors

Rear Modified Reflectors

Intermittent Wiper Control and Electric Washer Pump

Healeys have wipers that operate at one speed – slow! As original, they were not particularly effective. To address the problem, some Healey owners installed a later Lucas two-speed motor. I came upon an article by Ed Esslinger on a Sunbeam Tigers site who put together a kit to provide unlimited variable control of the speed of the Lucas wiper motor. I got in touch with Ed and purchased his kit and installed it in the Bloody Beast. I installed the control knob for the rheostat under the left hand corner of the dash fascia – hidden out of the way, but easily accessible. The kit can even be wired to accommodate most state laws that now require your lights to be on when the wipers are functioning! The lights come on automatically. On those misty days or when there is light snow the intermittent feature is really nice. This is the instruction sheet: Wiper Control and a wiring diagram:

Wiper Control Diagram

Wiper Control Diagram

Intermittent Wiper Kit

Intermittent Wiper Kit

Wiper Rheostat

Wiper Rheostat

Another suggestion I picked up from a web site was to convert the manual washer pump into an electric pump by placing a micro switch inside the little aluminum canister. I made this conversion, and then mounted a late model AH Sprite electric pump on the interior side of the firewall. One light touch activates the pump! I know, silly, cute and bordering on absurd,  but then was the time to do it! Outward appearance is completely stock. Here are the directions:  Rose Elect. Washer Pump Comp.

Washer Pump

Washer Pump

 Audible Turn Signal

I had installed a little Radio Shack “beeper” in the Bugeye because the run signals are not self-cancelling. Although the Big Healey control head or trafficator is self-cancelling, I thought I would go ahead and add it to the Bloody Beast as well. It is hidden on the fascia support bracket near the steering wheel shaft.

Turn Signal Buzzer

Turn Signal Buzzer

Toggle Switch Panel

I needed a few additional toggle switches, but did not want to add any to the dash as I wanted to keep it looking original. So I made up a little panel from a piece of aluminum angle, painted it red, and to avoid drilling any new mounting holes, I mounted it to two of the three legs of the wiper motor. The panel includes a warning light for when the driving lights are operational, a toggle for my redundant fuel pump (See Fuel System), and a toggle for the interior and boot courtesy lights.

Toggle Switch Panel

Sound System

Initially, my plan was to install an amplifier and “hidden” speakers to use with an iPod or iPhone. I was not interested in adding a radio to the mix. However, after reading about Roger “AUSMHLY’s”  installation of Creative self-powered computer speakers in his car, I decided to go that route instead. The system supports and iPod and does not include a radio. Similar speakers are now available from Creative that work wirelessly using Bluetooth technology. http://us.store.creative.com/Creative-T12-Bluetooth-Wireless-Speakers/M/B00408GUNY.htm The speakers are hidden under the dash. One above the parcel tray and the other to the left of the steering wheel.. The speakers sound great around town at lower speeds, but their output is overwhelmed by road noise at higher speeds. To help with improved output I added a sound booster “Boosteroo T794” from Upbeat Audio to my system. http://www.amazon.com/Upbeat-Audio-T794-Connection-Applications/dp/B000EES34W The Booster was well worth the small investment. For a discussion of sound systems and speaker placement, see this British Car Forum thread:

http://www.britishcarforum.com/bcforum/ubbthreads.php/topics/534047/10.

Creative Speakers

Creative Speakers

Boosteroo

Boosteroo

Cooling/Heater

Managing the heat generated by the operating engine, whether in the engine itself, in the engine bay, or in the interior is an issue in the Big Healey. What may not have been an issue in more temperate Great Britain, is a different story in the U.S. Over the years Healey owners have gotten progressively better at managing the heat issues. I made a number of enhancements to The Bloody Beast to help with cooling or at least improved insulation from the heat.

 The Original Cooling System

The capacity of the cooling system, excluding the heater, is 21.6 U.S. pints. The original thermostat was 158 degrees.

Cooling System Modifications

Aluminum Radiator

Recoring the original radiator with a more efficient tubing system is one option pursued by many enthusiasts, another is replacement of the original radiator with an aluminum alternative.  I chose the replacement route with an alloy radiator sourced from Cape International. In addition to the benefit of improved cooling, the polished aluminum header tank looks great in the engine bay! I painted the core with black radiator paint so that the “X” brace in the front of the car would “disappear” when looking through the grille.

Aluminum Radiator

Aluminum Radiator

Air-Intake Deflectors

The Healey has a multi-piece air-intake deflector assembly as original equipment; however, I was not happy with the gap that exists between the assembly shrouds and the radiator. This permitted air to escape around the radiator into the engine bay. The original deflectors are also a bit of a pain to install. I decided to fabricate some deflectors from aluminum stock. After constructing cardboard patterns I had the aluminum bent at a metal working shop. The deflectors are slotted to fit alongside the radiator in the standard radiator mounts to the frame. The image below shows the fitting of the deflectors before the radiator core was painted. As you can see this produced a tight fit around the radiator sides – no air escapes now!

Radiator Baffles

Radiator Baffles

Upper Radiator Shroud

My friend, Mick Nordquist, had an upper shroud made for his Healey radiator to keep the air coming through the grill directed to the radiator rather than escaping over the radiator. He supplied the pattern for me and I had one cut with a plasma cutter from 2mm aluminum plate and installed it with four stainless steel #8 self-tapping screws. In addition to improving cooling, I think it also offers a nice cosmetic improvement.

Radiator Top Shroud

Radiator Top Shroud

Coolant Recovery System

The original cooling system design provided for no ability to capture coolant whether just an expansion tank or a true pressurized recovery system. Healay owners, particularly if they have filled their radiators to maximum capacity are use to their car’s “burping” in the parking lot after being driven. I purchased my coolant recovery system components from Cape International.

Coolant Recovery System

Coolant Recovery System

Six Blade Stainless Steel Fan with Spacer

A number of alternatives to the original fan are available to the Healey owner today. The “Texas Cooler” and the variable pitch stainless steel fans are probably the most popular. I initially decided to go with the stainless fan available from British Car Specialists. However, the fan is pretty noisy so I switched the fan in 2020 for a nylon/plastic asymmetric fan similar to the “Texas Cooler” fan. The new fan was sourced from AH Spares. Time will tell but the new fan seems to keep the engine temperature under control and it is quite a bit quieter than the stainless steel fan.

Stainless Fan

Stainless Fan

AH Spares Fan

Fan Shroud

The custom air deflectors improved air control on the intake side of the radiator. To help channel the air on the fan side of the radiator and to add a safety component (those stainless fan blades are very sharp!!) I added a two piece shroud also available from British Car Specialists. It did not fit exactly as it would to the stock radiator, but a little tinkering and it fit beautifully. Since it was added after the restoration of the Bloody Beast was completed, I can say that the shroud was definitely responsible for some additional temperature reduction.

Radiator Shroud

Radiator Shroud

Radiator shroud

Radiator shroud

The Original Heater/Interior Cooling

The original heater was a Smith’s hot water circulating unit, part # 8G9048. It was assisted by a fan blower secured to the right front wheel arch assembly. Fresh air was supplied to the driver’s side of the interior by a 4” paper/metal hose controlled by a fresh air assembly mounted at the front of the car.

Heater/Interior Cooling Modifications

Sealing all of the holes in the firewall is the first thing to be done if one is to keep the heat and fumes out of the interior. A helpful tip someone shared with me was to wait until dark and put a light in the engine bay. This way any holes or leaks can be easily spotted from the interior.

Dynamat Extreme and Aluminum Duct Insualtion

A number of products are on the market to help reflect heat and offer both heat and sound insulation. Dynamat Extreme is certainly on of the most popular. I applied Dynamat Extreme heat reflective and sound insulation material to my interior first. I then applied aluminum duct insulation on top of the Dynamat and under the carpet. All seams were sealed with aluminum tape. These two together have proven to be very effective in keeping the heat out!

Dynamat Extreme

Dynamat Extreme

Aluminum Duct Insulation

Aluminum Duct Insulation

Modern Heater

For those (rare) occasions when I would choose to have more heat in the interior spaces, I chose to replace the Smith’s Heating unit with a contemporary unit supplied by Cape International. This unit has an internal two speed fan.

Cape International Heater

Cape International Heater

Fresh Air Supply

The original design of the car provided for some fresh air being delivered to the LH driver’s side of the car. Given that the Cape International Heater has its own fan, that left the original Smith’s blower to be used to blow fresh air into the passenger side of the car. I installed an air intake valve (upside down) just like the one on the LH side of the car, on the RH side, and then wired the blower to provide fresh air on the passenger side when desired. To be honest, I have found this to be useful for some ventilation when one has the hardtop in place, otherwise I am not sure that it was worth the effort! There are more details about this project in the restoration blog.

Ventilation Hose Assembly

Ventilation Hose Assembly

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Clutch/Gearbox and Propshaft Assorted Modifications

The system consists of the clutch, gearbox, overdrive, and propshaft. The original driveline system included the following:

Clutch: 10” Borg and Beck hydraulic

Gearbox: “side-shift” 4 speed

Overdrive: Laycock de Normanville electric

Propshaft: Hardy Spicer universal joints

Flywheel: 28 lb.

Driveline Modifications

Toyota 5 Speed Conversion

Although I always enjoyed the Laycock de Normanville electric overdrive in my car, I knew my tranny needed to be rebuilt. Rather than go that route, I took advantage of Smitty’s five speed conversion kit and installed a Toyota gearbox in the Bloody Beast. The Toyota Gearbox is quite a bit lighter and folks say that it runs  a bit cooler than the original box.

Gearbox and Bell Housing Installed

Gearbox and Bell Housing Installed

You can use a number of different Toyota gearboxes from the non-turbo Supras or from several of the 2 wheel drive pick-ups. I used a W57 1998 Toyota Tacoma 4×2 VIN# 4TANL42N2WZ094878. Details are available in the restoration blog, but this pdf document put together by Tracy Drummond is very helpful. Drummond Five speed gearbox conversion.

The kit includes several custom components including a bell housing casting unique to the conversion.

The kit is no longer available from Smitty, but Pete Delaney now handles the product. His contact information is as follows as of July 10, 2012:

Stephanie & Pete DelaneyHealey 5 Speed
P O Box 561
Harrisburg, NC 28075
704-455-2585704-455-8504 FAX
Healey5Speedaol.com

Clutch Conversion

Many who have the early 3000s and who complete the 5 speed conversion also adopt the BJ8 9/12″ diaphragm clutch. It is less demanding on the left leg muscles. I went ahead and made this conversion while I was at it. This also requires using a BJ8 flywheel. I obtained a 24lb. lightened flywheel from Bill Bolton.

BJ8 lightened Flywheel

BJ8 lightened Flywheel

Slave Cylinder Bleeder Pipe Extension

Anyone who has bled a Healey slave cylinder knows that the bleed nipple is not exactly easy to get to. Doug Reid aka “Mr. Finespanner,” fabricated an extension for me that makes the job much easier with the bleeder actually accessed from the engine bay. This has now become a popular item used by many aficionados.

Slave cylinder bleeder

Slave Cylinder Bleeder Extension

Slave cylinder bleeder extension

Slave Cylinder Bleeder Extension

Custom Propshaft

Installing the Toyota 5 Speed does require making up a new propshaft, which I had done at a local speed shop. The propshaft does need to be balanced prior to installation.

Propshaft

Propshaft

 

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Jule Enterprises Frame

The Original Chassis/Frame

The car’s chassis had been lengthened for the rear seats in the production of the 100 six BN4. Other than the change for disc brakes, there were no significant changes for the 3000. 100-6_3000 ChassisDesign.

Modified Chassis/Frame

Storage in damp surroundings plus over forty years of life left BT7 L4422 with substantial rust and corrosion. It was a difficult decision, but since I was building a “driver”, I decided to use Martin Jansen’s Jule Enterprises frame. My sons and I visited Martin’s shop just outside Toronto, Canada before making the final call. http://www.jule-enterprises.com/Martin is a great fellow with whom to work. He and Don Stewart substituted Martin’s new frame for mine and reinstalled the tub superstructure, including the replacement of several panels such as the floors in the interior and in the boot.

Martin Jansen's Frame Building

Martin Jansen’s Frame Building

Martin Jansen's Tub Reconstruction

Martin Jansen’s Tub Reconstruction

Martin Jansen's Tub Reconstruction

Martin Jansen’s Tub Reconstruction

The Jule frame uses 1/8″ wall by 3″ x 4″ steel rectangular tubing for the frame rails. The frame has a static bending strength 40 percent greater than the original, reducing frame deflection. Torsional strength of the Jule replacement is a 140 percent improvement over the original. The downside of the modern substitute is 80 additional pounds: 135 vs. 215 lbs. http://www.jule-enterprises.com/wp-content/uploads/2012/07/asurefoundation.pdf

Arrival Day: Marty, Scott, John, Lin

Arrival Day: Marty, Scott, John, Lin

The purists ( I don’t use that term in a disparaging way at all), will not like Marty’s frame, and the hobbyist may be confounded by finding the proper alignment of mounting holes in the frame or in replacement superstructure panels; but, it is hard to dispute the improvement in ride quality. My car is now rock solid, no creaks and twists, just great handling with a firm solid ride!

Front View Superstructure

Front View Superstructure – Before

After all of These Years

After all of These Years

Primed and Ready for Paint

Primed and Ready for Paint

Red Frame Curing

Red Frame Curing

Mounted to Move

Mounted to Move

Rear Tow/Tie Down Hooks

Tow/Tie-down Hook

Tow/Tie-down Hook




Rear Tow/Tie Down Hooks

I noticed on the Tom’s Import Toy Sales http://www.tomsimport.com/new/parts/parts.asp?sect=20&new=1 web site that he sells a nice replica of the factory tow hooks. They are made of high grade stainless steel and fasten to the car using the rear leaf spring bolt. I ordered a pair and was quite pleased with the quality. See images below:

Hook Installed

Hook Installed

Hook Installed

Brakes

The front drum brakes of the 100-Sixes were replaced by Girling 11” disc brakes on the 3000 in March 1959. Rear brakes were 11” Girling drums that were also controlled by a handbrake lever located on the right side of the gearbox tunnel

 Brake Modifications

The most significant modification I made to the braking of the 1960 MKI was the conversion of the rear drum brakes to disc brakes. This was accomplished with a kit based on Jaguar calipers coupled with mini-handbrake calipers sourced from Cape International. New rods to connect to the balance lever are supplied so that the handbrake functions as original. This is a pdf file of the instructions provided by Cape International.Cape Int Disc Brake Conversion 1

Rear Disc Brake

Rear Disc Brake

Handbrake Lever

Handbrake Lever

Aeroquip Braided Stainless Steel Hoses

Original-style rubber brakes hoses were replaced with stainless braided hoses also sourced from Cape International.

Stainless & Braided Brake Lines

Stainless & Braided Brake Lines

Drilled Front Brake Rotors

While standard rebuilt calipers were used in the front, the rotors were replaced with drilled rotors supplied by Cape International.

Drilled Front Rotors

Drilled Front Rotors

Speed Bleeders

I utilized the new technology for brake bleeders, Speed Bleeders. These bleeders have a small stainless ball in them that close off the release of brake fluid, making the process of brake bleeding much easier.

Speed Bleeders

Speed Bleeders

Recent production of the hydraulic brake switch has not produced a reliable switch. A remedy to the situation is to use a mechanical brake switch first developed by hot rodders. I sourced the switch I used from Watson’s Street Works. A description is provided in this Watsons mechanical brake switch.

Watson's Brake Switch

Watson’s Brake Switch

Watson's Brake Switch

Watson’s Brake Switch

 Brake Reservoir Canister Gasket

Other Healey restorers had noted that if overfilled, hydraulic fluid could slosh out of the vent hole in the reservoir cap and ruin the paint. Ever resourceful contributors to the British Car Forum discovered that a simple little gasket available in most auto parts stores fit perfectly in the reservoir cap, thereby solving the problem. I used one of the se “HELP” gaskets, #42072 in the Bloody Beast.

HELP Gasket

HELP Gasket

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Gas Strut Installation

 

Boot Lid Strut

Boot Lid Strut

My friend Steve Thomton has an on-line gas strut business. So, it was only natural that he should come up with the bracketing and appropriate strut to install a strut in the boot of a Healey. As always, Steve’s work is of the highest quality. The components in Steve’s kit are remarkably well made. At the time I am writing this, he sells his kit for $129.00 which I consider a bargain. The kit consists of four primary components: the boot lid bracket, the shroud bracket, the shroud brace, and the strut with appropriate mounting hardware. Steve furnished excellent written instructions making the installation straight forward. Everything was in place and operational in under an hour.

I love this additional “personalization” of  The Bloody Beast and would recommend it to everyone. It is so much more convenient than the folding rod as originally supplied.

This is a link to the instruction pdf: Trunk Gas Strut Install Instructions

These are the brackets fabricated by Steve:

Shroud Bracket

Shroud Bracket

Boot Lid Bracket with Collar Nuts

Boot Lid Bracket with Collar Nuts

Boot Lid Bracket

Boot Lid Bracket

These are the collar nuts and split washers used at the boot lid bracket:

Collared Nuts, Split Washers

Collared Nuts, Split Washers

These are installation images (the last one in Steve’s car ( I didn’t have the creativity to take a delayed shutter shot in the boot with the lid closed!)

Lower Brace

Lower Brace

Strut Installed at Boot Lid

Strut Installed in Boot Lid of Steve’s BJ7