Aug 212013

This is more of a retrospective post as the IRS rebuild was originally completed in line with the indicative chassis completion date of May 2011 given by Hutsons. I had stripped and painted all the components but needed a specialist to address the differential. By chance I decided to get it done by Alan Slawson from AJS Engineering.

I wasn’t aware at the time but one the two Jaguar World books that persuaded me to buy the E-Type included a section covering the IRS rebuild. Alan was the person they entrusted to do their rebuild so it seemed fitting he would also be doing mine.

When I arranged to pick up the diff I asked him if he would be prepared to do the full IRS rebuild. Although he was semi-retired he agreed, as long as I wasn’t in a rush for it. The aim was to free me up to tackle the 101 other things needed to be ready for the return of the chassis.

In the end Hutsons took much longer than hoped due to a very healthy backlog of restorations. It was shame really as I’d have preferred to rebuild it myself and would have had ample time to do so. Several months after dropping the parts off, Alan had completed the IRS and even drove over from Essex to drop it off. At his suggestion Gaz adjustable shock absorbers were fitted in preference to the Koni Classic ones I’d supplied.

Also at his recommendation was to rotate the larger radius arm bush through 90 degrees. The rubber section has two elongated holes which are normally orientated so they are front and rear. Rotating the bushes so the holes are at the sides marginally increases the fore and aft stiffness, which is in the direction of forces through the radius arm. I subsequently found out that this is common practice.

The IRS unit is quite a heavy unit so I knocked together an amply sized trolley using two sheets of 22mm chipboard. Great for moving it around but the down side of its generous proportions was that it bent significantly under the weight.

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