Jon continued with detailed mechanical and electrical tasks on our 1956 Jensen 541, beginning by swapping the bonnet securing catches on the lower edges for alternative units. The bonnet stays were also exchanged for silver-finished replacements. The rocker cover was removed, a new gasket was fitted, and the cover was securely refitted.
Work progressed to the door steps, where the old covers were removed and replaced with newly cut and trimmed items, which were then drilled and fastened in place. During checks on the nearside door, Jon found the lower hinge bolt missing. He removed the remaining lower bolt, slackened the top hinge, and adjusted the door outward. The lower hinge hole was enlarged to allow proper positioning, and the hinge was resecured with a new bolt, improving the door’s fit. The alloy trim at the rear edge of the door was removed to access the door lock, which was then resecured. The trim was refitted using new screws, resulting in better door closure.
Attention then turned to the battery terminals. A poorly executed previous repair on the negative terminal was corrected by removing the bodged connection, cutting it off, and repurposing it as a joiner. A fresh length of earth wire was made up and fitted with a new terminal, which Jon drilled and tapped to accept two modified 6mm bolts to clamp the cable securely. The battery was installed, the new earth lead fitted, and the joiner taped for protection.
The brake servo was then refitted. The associated pipe was cut to length and installed as the servo was lowered into position, then mounted and secured, with all pipework connected.
Jon began disconnecting wiring at the fuse box, labelling each wire for clarity. New leads were made for the ignition coil and connected, with an old connector block being replaced to bring the wiring closer to the original specification. The positive battery terminal was also addressed, having come off by hand. The cable was properly secured to a new terminal, and a battery hold-down kit was modified to fit. Jon drilled holes in the battery cage to mount the rods, then fitted the bracket and secured the battery. With both terminals connected and secure, the distributor cap and HT leads were refitted.
An attempt to start the engine via the dashboard start button was unsuccessful, so Jon tried again directly from the solenoid under the bonnet. The engine turned over and started successfully, with all gauge readings confirmed before switching off.
Further tasks included removing the metal vacuum pipe from the tank, trimming it to size, and refitting it with a blanking cap. The brake servo was rubbed down and painted black, ready for final installation the following day.
Jon continued with electrical work by removing seized screws from a damaged connector block, which was replaced with a new unit. Connections were started and tested progressively. He also rewired the under-bonnet lights, reconnecting them correctly to restore functionality. At this stage, the focus remained on getting systems operational, with wiring to be tidied once testing is complete.
