1961 E Type FHC (885036)
Total Team CJ restoration


Specification (briefly) for this project is as follows:

Total restoration of the 36th E Type coupe built. The car will feature a high performance CJ Stage One engine, triple Weber carbs, a CJ5/600 five speed transmission and a host of Team CJ performance and reliability upgrades.


Putting the finishing touches to another Stage One engine rebuild.

Oil pan drain plug boss was welded up and machined flat
New threads cut for the drain plug



Uprated ARP main cap bolts
Measuring deck height



All CJ forged pistons now installed



All that remains is to install the polished cam covers


Repairs and machine work completed on cylinder head, huge gains on the flow bench...

 Corrosion ground away from water jackets
 Water jackets then welded up in Coachworks



 Surfacing welds so we can bolt head to straightening plate
Head on straightening plate in oven 



 Flow testing head after port work
 Base line test results



 More than 60 cfm gained by port work - huge gains
 Front of head cosmetically polished



 Water jackets re-shaped, deck surfaced
Time to assemble this Stage One head 

Early pedal box modified for use with later master cylinder and booster..





We have now completed your IRS rebuild.

Larger front calipers and pistons have been rebuilt and installed on 
the rear - front brakes will be converted to vented Wilwoods



Rear suspension features Koni shocks and uprated CJ springs
Assembling the rear hubs



Very early hubs do not have water throwers between
the hub and the hub carrier
 Ray putting the final touches to your IRS rebuild



Base line flow testing your cylinder head prior to port work
Pressure testing cylinder head


Pulling down sleeves prior to surfacing the block and mocking up main bearings to calculate requisite crankshaft journal sizing...



The following sequence of photos show the align hone and cylinder hone in progress....






Getting your Stage One engine rebuild underway...

We had to use the crane to remove your cylinder head
Pistons were seized



Old school knurled pistons

With the last couple of repair panels now welded in place, it is time for some lead loading.

Wurth Body wax is applied to all inner surfaces before
the side cowl panels are welded in place



Replicating early style 'two piece' door skins
Old door top panel being fitted to new door skin



Old panel is spot welded in place on new skin



Lead loading the welded seams


The following sequence of photographs show us fabricating some complex repair panels to restore the nose of your bonnet to its former glory.




A hand made wooden buck will be used to form the required 
shape for the upper part of the bonnet mouth



Repair panels are then hammered over wooden buck



The 3 repair panels are then tack welded together



After metal finishing, welds are invisible
New nose is then tack welded in place



The seam is then TIG welded



Welded seam is then ground away



Cosmetic surgery, CJ style...


After a lengthy delay caused by an apparent world shortage of new engine frames, I am pleased to report that we now have this project back underway. Fitting the bonnet was something of a challenge as the bonnet itself was more than an inch too short. The solution was to weld additional sheet metal across the rear edge of the bonnet to close up the gap at the cowl.

Arrival of new engine frames allowed us to start fitting bonnet



Even with extra thow CJ hinges and all the (fore/aft) shims removed, 
the bonnet was still more than an inch too short
The solution was to weld additional sheet metal along
the rear edges of the fenders and center section






The extension is first tack welded in place, then the
resulting seam is TIG welded



After the weld is cleaned up, the repair is invisible



Next up - some major repairs to the nose of the center section


Darrell has now installed the front cowl panel he fabricated a couple of weeks ago, and has also fabricated and installed a repair panel for the left hand rear quarter panel/wheel arch.

Trial fitting new front cowl
Fabricating a new side cowl panel
Side cowl panel is shaped to match contour
of leading edge of door skin
Trial fitting side cowl panel with
new front cowl panel
Spot welding front cowl panel in place
Left rear wheel arch next up...
Fabricating and trial fitting a new
wheel arch repair panel
Panel is first tack welded in place
Seam is then TIG welded
TIG bead is then ground away leaving
an invisible repair
Inner wheel arch also requires
extensive repairs
New inner wheel arch panel was
Wurth Body Wax is applied to all
inner surfaces
Seam between rear quarter and sill
is lead loaded
Door fit already starting to take shape
Rear tailgate fit is very poor and will
require extensive work


Installing new floors and outer sills...

Trial fitting new outer sills
Wurth Body Wax applied to all
inner boxed sections
Outer sill spot welded to outer
edge of new floors


Fabricating and installing new panels for the right hand side of the transmission tunnel...


Installing new inner sills...

 Wurth Body Wax is applied
to all closed box sections
Trial fitting the RH inner sill 
 Sill stiffeners welded in place

The bodywork restoration is now underway...


Back from the blasters, everything is pretty much as expected with the exception of the nose of the bonnet center section, which is very rusty.

Nose of center section very rusty
Some of the panels that will
be required

The following sequence of photos show Darrell fabricating a new sceen cowl panel from 18 gauge sheet metal.

 Making a template from the original,
rusted cowl panel
 Shaping on the sheet roller



Gerardo assists on the bead roller
Forming the screen seal edge

Cutting away corroded sheet metal to give the media blaster the best possible access to all inner panels and box sections...

Very early style 2 piece door skins
Cowl panel has perforations 
and will be replaced
Underside of cowl panel
Rear clip will be replaced
Bodyshell now ready for blasting
Disassembling the bonnet

We are delighted to get the restoration of this very early coupe underway. Our first task, after disassembly, will be to cut away the corroded sheet metal and have the car media blasted.



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