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Technical
Most Technical Articles are PDF files so that you may print copies.
Click on the links below to get to the proper section.
Some files take a LONG time to download.
No representation is made as to the trustworthiness of any vendor listed herein with the exception of
those noted in the "My Modifications" section with whom I have personal experience.
Body
Brake/Clutch
Carpeting/Interior
Competition
Electrical
Engine
Fuel System
Gauges
Heater
Ignition
Insulation
Miscellaneous
My Modifications
Overdrive and Transmission
Safety
Suspension
Trafficator
Wiring Harness
Don Hardie's Healey 100 Articles
(Articles collected over the years and graciously donated to this site by Don)
See Steve Thornton's excellent site for articles covering many exotic modifications.
Go to the Links page, Best of the Best Section. Also if you are still stumped, go to the Miscellaneous section
of this page and and click on the link to Steve Gerow's site. Lots of great "stuff".
Look also in the Service Bulletin and Important Links sections for more Technical Information.
Body
Article Subject/Link
BJ8 Top Installation Instructions
C
ourtesy Jim Werner
Battery Access Lid
Captive Nuts on a Jule Frame
Dash Lamp Removal BJ8
C
ourtesy Jim Werner
Door Striker Plate
Floor Panels
Hard Top ID
C
ourtesy Jim Werner
Hard Top Installation BN6-BN7
Hardtop Parts List BN6-BN7
Hardtop Restoration
Hardtop Restoration BN6-BN7 John Homenek
Hood Bows BN1 Second Series
Hood Bows BN1 Third Series
Lamp Lens Renovation
Rocker Panel Curvature
Waxoyl - Homemade
Windshield to Body Seal
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Brake/Clutch
Article Subject/Link
Brakes. Everything you want or need to know.
This is a 28 page PDF.
Brake and Master Cylinder information
Girling catalog contains their part numbers and brake and cylinder sizes.
Brake Light Switch Repositioning
Brake Light Switch Tip
C
ourtesy Jim Werner
Brake Line Routing on a BJ8
Clutch Alignment Tool Homemade
Clutch Line Clips
Disk Brake Squeal Removal
Drum Balancing
Emergency Brake Cable Installation
C
ourtesy Jim Werner
Emergency Brake Mechanism = Exploded View
Excessive Disk Brake Pad Wear
Firewall Clutch Tubing Routing
Servo Servicing
C
ourtesy Jim Werner
Vacuum Server Repairs different units.
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Carpeting/Trim/Interior
Article Subject/Link
Armorcord Installation
Arm Rests
Arm Rest for a BJ7 with Hidden Compartment
BN2 Tonneau Installation
BN2 Tonneau Fasteners
BJ8 Boot Armorcord Installation
More on Boot Installation
BJ8 Carpet Install
BJ8 Dashboard Alignment
Carpet Installation
C
ourtesy Jim Werner
Carpet Installation BN6-BN7
Carpet Installation Gear Box Cover
Carpet Installation Battery Door BN6-BN7
Dashboard Refinishing
C
ourtesy Jim Werner
Dash Installation Steady Bracket
Door Interior Trim
Door Shut Face Finisher Set
Glove Box Guide
Indoor Seals and Trim
Removeable Seat Belts BJ8
Restoring Bakelite
C
ourtesy Jim Werner
Scuttle Seal Installation
Side Curtain Bracket Finish
Sill Plates and Trim
100-4
Top Frame Mounting Plate BN1
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Competition
All articles in this section should be read together as they are somewhat interrelated.
Competition from Sports Cars Illustrated 1958
(External Link) Courtesy Rick Wilkins
Engine Modifications for Competition 1961 Article
Courtesy Patrick Yoas
Engine Modifications for Competition Dyno Testing
Patrick Yoas
Healey with a V8 PUNCH
Courtesy Patrick Yoas
More Horsepower for your Healey
PDF Courtesy Patrick Yoas
More Horsepower for your Healey
Microsoft Docx format loads faster
Ruddspeed modifications 1960
Courtesy Patrick Yoas
AH Le Mans conversion
From Motor Sport magazine, February 1956
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Electrical
Article Subject/Link
All About Relays
Everything you need to know.
All things about Fuses and Relays
Originally written for a Sprite but is relevant.
All things About Fuses - More from Wikipedia
Alternator Bracket Construction
Alternator Conversion Positive or Negative Ground
Alternator Conversion - Another method including photos
Alternator Installation
(
Denso Alternator Conversion
)
BJ8 Driving Light Switch Addition
Courtesy Jim Werner
BJ8 Lamp Mount Fabrication and Installation
BJ8 Wiring Diagram
Battery Cutoff Switch Tech Tip
Courtesy Jim Werner
Battery Cables - Cloth Covered
Conversion of Reflectors to LED
Distributors Explained
Driving Lights on a BN6 with an Alternator and Smitty Tranny
Flasher Can Location BN2
Four Way Flasher Installation
Courtesy Jim Werner
Four Way Flasher Another Method
Fuel Pump Cutoff Switch
GPS or Cell Phone Charging on a Positive Ground Car
Head Lamp Relay Wiring
Horn Repair
Courtesy Jim Werner
Improved wiring for Headlight Circuits for Halogen Bulbs
Installation of a Bose Stereo System in a BJ
8
Installation of Radio and Speakers
LED usage
Relay Box Rebuild using DPDT relays instead of solenoid and contacts
Recharging Optima Batteries
Trim Your Antenna
C
ourtesy Jim Werner
Voltage drop
Wiper Motor Repair Tip
Courtesy Jim Werner
Wiring Color Codes
Wiring Color Codes another version
Wire Size and Power Limits
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Engine
Article Subject/Link
Air Filter Cover - Increase your Filtering power
Capillary Tube Mounting Strap
Coolant Recovery System
Cylinder Compression Pressure Table
Engine Casting Date
Engine Cradle
Engine Dolly
Engine Fittings
Engine Mounts
Falcon Exhaust Problem and Solution
FIring order of a 6 cylinder engine -- 15 too young -- 36 too old-- 24 just right
Not a link.
Fitting 14" Fan
BJ8
Freeze Plug Installation
Installing a Flywheel Ring Gear
Courtesy Jim Werner
Installing K&N Air Filters
Courtesy Jim Werner
Installing a PCV Valve
Oil in Cooling System Repair
Overheating
Rocker Arm Rebuild
Courtesy Jim Werner
Starter Dog Nut Tip
Courtesy Jim Werner
Startup Procedure After a Rebuild
Sump Protection
Thermostat Check Device
Check your thermostat while in the car.
Thermostat functions
by Simon Lachlan
Thermostat Tips
Courtesy Jim Werner
Timing Cover Seal
Courtesy Jim Werner
Top Dead Center
Tune Up Clinic
Water Valves
(Taps)
Courtesy Simon Lachlan
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Fuel System
Article Subject/Link
Carburetor Coupling
Choke Return Spring Tip
Courtesy Jim Werner
Emergency Fuel Gauge
SU Fuel Pump Repair
SU Fuel Pump
s
External link to Dave DuBois's site. Everything you want to know about SU Fuel Pumps.
Gasohol additives to remove water.
HD Carb Adjusting
HS6 Carb Adjusting
HD8 Carb Adjusting
Replacing Carb Throttle Bushings
Second Fuel Pump in Series
Second Fuel Pump Alternate Method
SU Carb Adjusting
SU Carb and Fuel Pump Manual
Very long 84 page manual in PDF format.
SU Carbs Basic Theory
Throttle Shaft Reaming
Tuning SU Carburetors 1955 Article
(Takes a while to load)
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Gauges
Article Subject/Link
BJ8 Tachometer Reads High
Courtesy Jim Werner
Calibration of Smith's Tachometer
Changing Tachometer Polarity
Erratic Fuel Gauge Fix
Fuel Gauge Condensation
Courtesy Jim Werner
Fuel Gauge Tips
Courtesy Jim Werner
Fuel Gauge Repair
When on the site, click on each photo for full narrative.
Rebuild BJ8 Tach
Speedometer Cable Routing
Speed Calculator
Opens in an XLS window
Speedometer Calibration
Another site to use. Take your Pick.
Speedometer Calibration Numbers
Speedometers - Just how do they work anyway?
Speedometer Repairs Healey Owners Experiences
Speedometer Repair
Smith's/Jaeger Manual
Temperature Sensor Removal Tool
Trafficator Repair
Very long PDF file.
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Heater
Article Subject/Link
BN1 Heater Installation
Heater Control Cable Replacement
Courtesy Jim Werner
Stuck Water Valve
Courtesy Jim Werner
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Ignition
Article Subject/Link
Distributor Fault Correction
Distributor Information
Courtesy Jim Werner
Ignition Timing Specs
Courtesy Jim Werner
Ignitor Ignition
Courtesy Jim Werner
Pertronix Ignitor and Flame Thrower Coil Installation
Rotor Comparison
Rotors with no Rivet
Spark Plugs
Everything you want to know. Navigate to the Spark Plug Help for lots of technical articles. Look also at the Manufacturers codes.
Spark Plug Coding
Vacuum Advance Specs
Courtesy Jim Werner
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Insulation
Article Subject/Link
Fire Wall Heat Shield Dimensions & Patterns
Drivers Side Heat Shield BT7
It can be printed at 1:1 and then used as a pattern. Kinko's or blueprinters can print it onto 24" X 36" paper.
Insulated Transmission Tunnel
Super Insulating
Courtesy Jim Werner
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Miscellaneous
Article Subject/Link
Annealing washers to make them oil tight
External link to another site.
Bead Blaster (Homemade)
Bead Blaster (Homemade) another version
Blackening Small Metal Parts
Blaster - Homemade Soda
Blasting Cabinet Tips
Brake (Sheet Metal Bending) homemade
Body Protection While Under Repair
Bolt Codes Page One (in Excel Format)
(Courtesy James Wilson www.healeyjournal.com)
Bolt Codes Page Two
(in Excel Format)
Bolt Codes from BMC Service Bulletin
Bolt and Fastener Codes for a BN2
Bolt Grade write-up and chart
Photo of almost every type of nut, bolt or other fastener
along with other information
Car Dolly on the Cheap
Cheap Signs
Courtesy Jim Werner
Chrome Exhaust Tips
Courtesy Jim Werner
Conversion of a 100 to a 100M
Cooling your car engine and interior
Creased Bonnet on a BN6
Courtesy Jim Werner
Cruise Control Installation
Drive On Ramps
Derust Solution (Homemade)
Drip Pan Fabrication
Keep Oil off of your garage floor.
Emergency Roadside Repairs
Fasteners for a BN2
This is an Excel spreadsheet that has been recently updated. The lines in gray have yet to be identified. More updates will be forthcoming.
Goodies from the Fertile Mind of Charlie Hart
Freeing Seized Nuts
Healey Spares for the Road - Introduction
Healey Spares for the Road Part Two
Key Interchange Data
KN Filter Modifications
Moss Motors Technical Videos on You Tube
Oil Filter Study
Oil - Everything you want to know and more
Oil Formulation
Letter from Castrol
Oil History, additivies, ZDDP
Courtesy Moss Motors
One Method of Raising a Car onto Jack Stands
Pedal Extension Brake and Clutch
Penetrating Oil Showdown
Which is best!
Protective Cover for the Shroud when Making Repairs
Restoration Rebuild order
Restoration Chassis Platform on Casters
Restoration of blackness on tools (Parkerizing)
See ordering information in the Miscellanous section of the Parts Suppliers page.
Road Rules for Group Tours
Courtesy Jim Werner
Schedule of Repair Times
Shelley Jacks explained
Shopping for Steel Tips
Socket conversion chart Whitworth to other sizes.
Speed Calculator
Steve Gerow's WONDERFUL Tech Tips. A must view!
If you can not find it elsewhere on this site, look here!
Technical Trivia
Courtesy Jim Werner
Unique Solutions to Common Problems
Water on Knees
Courtesy Jim Werner
Wire Wheel Removal
Courtesy Jim Werner
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My Modifications
Article Subject/Link
Addition of a new fuse block, mechanical brake light switch, third brake light, illuminated reflectors, fuel pump inertia switch, fusing the fuel pump, installation of Tow Eyes and Tie Down Hooks. Also, installation of a PCV Valve on a BN6, Coolant Overflow Reservoir, Heater cold air duct fastening and Clutch and Brake Pedal Extensions
Click here to view entire document
Click on the links below to view specific items
Fuel Pump Fuse and Inertia Switch
Third Brake Light, Mechanical Brake Switch and Lighted Reflectors
Fuse Block - Six Fuses
Tow Eyes and Tie Down Hooks
PCV Installation
Pedal Extension Installation
Coolant Recovery System Installation
Parts Sources
(More modifications to come such as installation of a second fuel pump in parallel with a cutover switch on the parcel shelf, as I get to them on my to do list.)
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Overdrive and Transmission
Article Subject/Link
Gear Box Dismantling Video
How Gears Work - External Link
Great animation.
Installation of Smitty's Transmission
Courtesy Jim Werner
Drive Shaft Balancing
Courtesy Jim Werner
Gear Ratios/MPH by Tire Size/Rear End, etc.
Overdrive Accumulator Piston
Overdrive Manual Section One
Refers to an installation on a TR but is the same unit as on Healeys.
Overdrive Manual Section Two
Overdrive Manual Section Three
Overdrive Manual Section Four
Overdrive Manual Section Five
Overdrive Oil Study
External link to the study
Overdrive Pump Pressure Gauge
Courtesy Jim Werner
OD Relay Repair
and Testing
Overdrive Serial numbers and Models
Overdrive Throttle Switch Disassembly
Overdrive Warning Light
Courtesy Jim Werner
Overdrive Warning Light and Simplified OD Wiring Schematic
Side Shift Transmission Removal
Troubleshooting the Overdrive Unit
Two Cent Overdrive Repair
Courtesy Jim Werner
Voltage drop
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Safety
Article Subject/Link
Audible Flashers
A video is on YouTube at:
Video of Audible Flashers
BJ8 Rear View Mirror
Courtesy Jim Werner
BMC Directions for the use of Knock Offs
Courtesy Jim Werner
C
ollapsible Steering Column Fabrication
Conversion of Reflectors to LED
Driving Lights on a BN6 with an Alternator and Smitty Tranny
Four Way Flasher Installation
Courtesy Jim Werner
Four Way Flasher Generic Installation
Four Way Flasher with Ignition Off Wiring
Headlight Adjustment
Horns Specifications
Illuminate Reflectors BN4 to BJ8
Rear View Mirrors. How to set to remove blind spots
Seat Belt Installation
Third Brake Light
See Important Links page Parts Section for a cheaper price for the same item than is shown in the article! See also My Modifications section on this page.
Third Brake Light Another Method
Tire Information
Courtesy Jim Werner
Tire Safety US Government Site
Page after page of information about tires
Wiper Blade Rubber - Replacement
Wire Wheels - they self tighten by design
(External Link)
Knock Off Hubs Original Patent Drawing
Use with the above link
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Suspension
Article Subject/Link
Bushing Replacement (Poly generic instructions)
Reinforced Mounts for Koni Shocks
Steve Gerow's solution including drawings and photos.
Koni Shock Installation
Nice to view before a purchase.
Lower Wishbone Inner Bearing Replacement
Courtesy Jim Werner
Replacing Rear Springs
Courtesy Jim Werner
Shock Catalog
Combination of two articles. See World Wide Parts in the Suspension section of the Vendors page to order.
Shock Absorber Information
Courtesy Jim Werner
Shocks, Fully Adjustable
Wheel Bearing Notes
Courtesy Jim Werner
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Trafficator
Article Subject/Link
Replacing a
Stator Tube
Courtesy Jim Werner
Removing Turn Signal Switch
C
ourtesy Jim Werner
Steering Wheel Replacement
Courtesy Jim Werner
Trafficator Repair
Lots of details and photos.
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Wiring Harness
Article Subject/Link
BN1 Wiring Harness Routing
How to Install a New Wiring Harness
Courtesy Jim Werner
Routing of Rear Chassis Harness
Updated Wiring
Writted for an MG but adaptable to your Healey.
Wiring Harness Bulb Sockets
Wire Gauge chart
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Don Hardie's Healey 100 Articles
100 TECHNICAL
AH Spares Retail price list 2008
AUSTIN HEALEY 100 PARTS LIST
KILMARTIN SHEETMETAL CATALOGUE BRITISH CAR SPECIALISTS 2008
LINKS & PHONE Nos.
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Page last updated on February 3, 2012 and is the intellectual property of John Sims,
The EMail Mechanic
© and/or the authors of the individual articles contained herein.
LInks tested December 14, 2011.
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