Need a body sealing plug

Talk about the E-Type Series 2

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tonyabacus
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#1 Need a body sealing plug

Post by tonyabacus » Mon Sep 29, 2025 7:59 pm

I have an S" LHD with aircon.

I have removed the aircon system as part of the changeover from LHD to RHD, but where the pipes go through the bulkhead, the factory created a tubular type recess leading from the interior through the firewall.

I now need a blanking plug to finish off the opening but try as I might I cannot locate one So does anyone have any thoughts as to where to get a blank rubber (or plastic) plug/bung please, the size of the opening is 51mm x 31mm (although I guess in the day this would have been an Imperial size (2" x 1.25"). I am based in the UK.
Thanks
Tony

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bitsobrits
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#2 Re: Need a body sealing plug

Post by bitsobrits » Mon Sep 29, 2025 10:26 pm

Sounds like a job for 3D printing.
Steve
'65 S1 4.2 FHC (early)

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vee12eman
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#3 Re: Need a body sealing plug

Post by vee12eman » Mon Sep 29, 2025 11:07 pm

If you can’t find one, you can make it from two layers of medium hard foam rubber, you just have to ensure that the glue sticking them together doesn’t go right to the edge, or trim it by cutting between the layers, where it fits over the body. A sharp knife like a scalpel is the best option. It’s hard to believe one will not be available for the E-type, but I have made very original looking body plugs for less well supported classics previously.
Regards,

Simon
Series III FHC

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mgcjag
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#4 Re: Need a body sealing plug

Post by mgcjag » Tue Sep 30, 2025 7:26 am

I havent had air con and can't think of where the pipes come through... whats used on non air con cars(part number)?.....Steve
Steve
69 S2 2+2 (sold) ..Realm C type replica, 1960 xk150fhc

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UK Muppet
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#5 Re: Need a body sealing plug

Post by UK Muppet » Tue Sep 30, 2025 10:15 am

With the original pipe housing removed from the bulkhead (pop rivets) simply make a plate to cover the hole and transfer the pop rivet holes to it so it can be riveted in place along with seam sealer to prevent any fumes from the engine bay. It cannot be seen from either side after everything is in place.

new cover plate

Image

original housing

Image
Tony
69 Series 2 2+2 auto

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tonyabacus
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#6 Re: Need a body sealing plug

Post by tonyabacus » Tue Sep 30, 2025 10:41 am

Tony
The last picture shows exactly how my car bulkhead is configured with that deep recess. The open grommet is the same, but I am looking for a blanking grommet to seal this opening. It appears most of the grommets available now are metric and slightly smaller or much larger than I need. I have trawled the Net quite a bit but with little sucess, although some of the other suggestions about making one's own may be the way forward, so thanks everyone.
Tony

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tonyabacus
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#7 Re: Need a body sealing plug

Post by tonyabacus » Tue Sep 30, 2025 10:49 am

Steve
It seems that this recess is only fitted to cars with aircon, according to one contact I spoke with. So I am guessing that at the factory any car designated to have aircon had a hole cut into the bulkhead panel and this recess panel inserted. As the recess panel is spot welded then I assume it was done before assembling into the car in question. The open end of the recessed panel needs to be closed off from the engine side to prevent the ingress of water and road debris, hence the need for a blanking plug/grommet.
Tony

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UK Muppet
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#8 Re: Need a body sealing plug

Post by UK Muppet » Tue Sep 30, 2025 11:01 am

Yes they are only fitted to LHD cars with aircon, mine was pop riveted in place (original) and had never seen a spot weld. It took maybe 1-2 hours to remove the housing and make up a plate to cover the hole, not difficult by any means and most likely much quicker than trying to make some sort of blanking plug out of foam rubber.

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Tony
69 Series 2 2+2 auto

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