Job # 1984 (DU) - Jaguar 4.2 E Type Full Stage One engine rebuild

Yesterday afternoon we installed your rebuilt carbs and fired up the engine for the first time. All systems were functioning perfectly. Earlier today we ran the car through four break-in heat cycles on the dyno and dialed the carbs in. The car is idling smoothly and pulling strongly.

Click on the photo below for a video clip of the car in action on the dyno.

 
I am pleased to report that your car is now safely installed at Classic Jaguar. Congratulations on putting together a great looking car, Dave!

Reported oil pressure problems...

After you were told by the shop in Santa Barbara that your freshly built Stage One CJ engine had no oil pressure, you will be pleased to hear that in fact she has excellent oil pressure. I can only assume that the Santa Barbara shop was using the (inoperative) gauge in the dash to determine the oil pressure, because as soon as we hooked up a mechanical gauge, we instantly had around 60 psi at cranking speed. Incidentally, the oil pressure gauge in the dash was not working because it had been wired backwards with the water temperature gauge. Total time invested so far - 10 minutes.

Onwards and upwards...

Next step is to install the carbs and fire the beast up!

Car will be test run on the CJ dyno later today	Engine was pre-lubed prior to cranking

We now have your engine and CJ5/600 five speed wrapped and loaded onto a pallet. It should be with you in the next few days!

I am pleased to report that your engine rebuild has now been completed.

We have now completed the repairs and machine work to the cylinder head and should have your engine assembled and ready to ship in the next couple of days.

Darrell welded up the corroded water jackets	Water jackets were then re-shaped on the mill
After surfacing, deck surface and water jackets good as new
	Base line flow numbers on the intake side
Nice pick up of about 45 cfm following porting

With the short block now completed, we are turning our attention to the cylinder head.

Short block assembly, continued...

Time to start assembling the short block...

Polish crank journals	Balancing the crank
Balancing flywheel and pressure plate	Crank now installed

I am pleased to report that we have now completed the block machine work. The following sequence of photos show Kevin measuring bearing clearances, honing the cylinders and surfacing the deck of the block. Next we will use the measured bearing clearances to calculate requisite crank journal sizing.

Measuring main bearing clearances after align hone	Torque plate used during honing process
	Surfacing block after cylinder hone completed
Painting interior of block with Glyptal

We have now completed an align hone and begun the cylinder honing process...

Align hone in progress	Main caps machined to perfection	Block then moved to cyl hone machine

The water jackets behind the cylinder liners were completely blocked on this engine. There were also a number of minor cracks in the cylinder walls and between the sleeves on the deck surface. None of these cracks represent a signififcant problem and will be dealt with during the resleeving process.

Cutting out old sleeves	Blocked water jackets behind sleeves
Cylinder walls also cracked

We now have your engine completely disassembled and the rebuild underway.

A number of head studs were seized and required a little 'heat'  before they would part company with the block
	Engine now completely disassembled

I am pleased to report that your engine has arrived safely at CJ and we will have the rebuild underway in the next few days.