PCBs
by Lorne Goldman

I happily admit to being a fan of the early Morgan Roadsters (2004-2006). They have a fine balance of weight and power making them very worthy successors to the Rover Plus 8s.  However, Roadsters were also the beginning of the end of a Morgan era. And though I believe it is merely a coincidence, Morgan design influences changed radically after Peter Morgan's passing in 2003.  Peter changed or added technology only when forced to by legislation or necessity. 

 After Peter's passing, the Factorywas made more reliant on outside designers and components. The cars have become less owner-friendly and the older, fiercely loyal community s withdrew, much like the Trikers did a three generations ago. The "Works" morphed into an assembly plant rather than a creator of parts. No one in the present generation of the Family has any mechanical experience. The world has rapidly adopted technology that discourages owner skills, not merely with Morgans but with all machinery.  Skills in have disappeared. 

The latest trad components and design are dictated by cost. Morgan has not thrown off much real profit since 2000 and there is constant pressure on current staff and management. This has prejudiced the final product. Examples are seen every day now on any Morgan forum with newer car owners participate. Where one could reasonably rely on an pre-1996 Morgan to run without a problems for a decade or so, this is no longer the case. Today's buyers are introduced have been trained to "they all do that" philosophy. Originally, the expression only referred to very old Morgans that required attention from lack of maintenance or usage! 

One of sadder, more frustrating components Morgan now uses to save money is a PCB or PRINTED CIRUIT BOARD. Used originally in computers, they have found their way into the automobile industry as a cost saver when wiring and to compensate for loss of skills. They can be made in many formats but the more common is a laminated board of connecting electronic/ electrical components using conductive tracks, pads and other features etched from copper sheets. Components are generally soldered on the PCB but advanced PCBs may contain components embedded or "printed" in the board itself. They can be single sided, double sided (two copper layers) or multi-layered. Special glass epoxies is the primary insulating materiel used for boards. However, Morgans produce a LOT of vibration and chassis flexing. :(

PCBs require a design effort to lay out the circuits, but after that, manufacturing and assembly can be automated and therefore each unit become very cheap. They cut down a huge amount of labour and assembly time. As well, PCB’s can control, feed, and direct the new automobile technology like AC, GPS, anti-lock brake systems, ECUs that control engines, ignitions, windshield wipers, headlights, safety items, security features and entertainment systems. Sadly, pretty much all PCBs cannot be repaired only replaced. The type of  testing and diagnosis for a century electrical testing is not effective. They must be replaced. They also prevent mechanic or owner intervention. Earlier Morgans could rely and change fuse-boxes, guided by diagrams and colour-coded wiring. PCBs prevent this. 

The world manufacturing centre for PCBs is China. It has many companies offering made-to-measure boards for even small manufacturers. Manufacturing circuits with PCBs is cheaper and faster than with other wiring methods as components are mounted and wired with one single part. 

SOLUTION FOR A DEFECTIVE PCB

Sorry, for the reasons indicated above, there is unlikely to be one. Even if we had the schematic of the errant board, it would not be of much help. They must be replaced, like-for-like and that is not a piece of cake. It IS possible to find a very smart auto-electrician and perhaps he can find a bypass or some jury-rigged solution to get you on the road again for a time. But a defective PCB will most likely continue getting more defective.

I am not in a position any longer where I wish to spend that much time (it is very tedious and complex task) to analyze and proof a replacement simpler) system.  I can point out that the earlier Morgan electrical systems (wiring and fuse-boxes) may have had less to deal with but they are not as sturdy as one would want either. Their advantage is that they are very approachable and very easy to sort, adapt or repair. The world's best (and cheapest) for high quality aftermarket auto electrical systems in the US and Australia.  I am planning to replace my 1984 fuse-box and wiring with something much better next summer. Watch this space. I will soon be able to advise you on exactly what you need for your model and year. However, beware. If you do not work on this yourself, the cost will be enormous.