1964 Jaguar E Type (AD)
Team CJ restoration


 

 
Specification (briefly) for this project is as follows:

Total Team CJ restoration with numerous performance and reliability upgrades

 
 

 

Another Stage One engine rebuild wrapped up in the CJ machine shop...

 
   

 


We have now completed the lead loading process along the right side of the car and turned our attention to the left....

 
Applying lead
Lead loading now completed along right side of body

 

 

 
Perfecting bonnet and door gaps with sheet metal and lead
 

 

 

 
 
Right hand door fit

 

 

 
Starting to apply lead to left side cowl panel
 


Fitting the new bonnet, lead loading continued...

 
 
 Wurth Body Wax applied to inner box sections

 
 
 

 

 
 Inner surfaces of side cowl panels also coated in wax
 Side cowl panels now welded in place

 
 
 

 

 
 Starting to look more like a car every day
 Lead loading the bottom bonnet gap between the
sill and the front wings

 


Installing the new bonnet, lead loading around the rear hatch and lamp area...

 
 
 We will begin fitting the new bonnet next week
 Lead loading underway at the rear of the car

 

 

 
 
 Trial fitting rear lamp housings

 


It is now time to assemble and begin fitting your new bonnet..

 
   

 

 

 
   


Having replaced substantial sections of both door frames, we trial fitted the window frames and chrome B pillars prior to installing the outer door skins.

 
 Trial fitting window frames
 

 

 

 
 
 Rolling the door skin flanges

 

 

 
 Trioal fitting RH cowl side panel with new door
 Almost time to assemble and install the bonnet

 
 


Lots of progress in the Coachworks....

 
 
   

 

 

 
Door frames have now been largely reconstructed
New tailgate gutter rail has been fabricated
and welded in place

 

 

 
Boot floor assembly has now been welded in place
 

 

 

 
   

 

 

 
Major surgery at rear of car is now complete
 

 


Rebuilding very rusty door frames...

 
 
Door frames are very rusty
 

 

 

 
   

 

 

 
   

 

 

 
   

 

 

 
 
Time to start fabricating some new panels and
reconstruct the door frames

 

 

 
 
This little panel has a lot of complex curves and is
extremely difficult to make

 

 

 
   

 

 

 
Top of door frame starting to look a lot better
Fabricating top drain panel

 

 

 
   

 

 

 
New top drain panel welded in place
Bottom of door frame has been cut away and will be
completely replaced

 
 


 
Rear of the car starting to take shape in the Coachworks...

 
Trial fitting replacement panel
 

 

 

 
   

 

 

 
Things have to get much worse before they can
start getting better!
 At this point, there isn't much left at the rear of the car

 

 

 
Tack welding rear panel in place
 

 

 

 
 
TIG welding rear panel seams

 

 

 
   

 

 

 
 
Fabricating more repair panels for the rear lamp area

 

 

 
   

 

 

 
   

 

 

 
Welds plaished and metal finished
Starting to look much better!

 


More progress in the CJ Coachworks...

 
 
Rear wheel wells had to be largely reconstructed before
the new boot floor assembly could be fitted

 

 

 
Almost ready to weld the new boot floor assembly in place
But first, the nasty panel above the rear license plate
will have to be replaced...

 

 

 
Trial fitting replacement panel....
Trial fitting hatch door with new panel...

 


The following sequence of photos show your Suffolk & Turley interior kit, as well as the repair of both inner and outer rear wheel arches...

 
 Tan interior will look fabulous against Gunmetal paint
 

 
 

 

 
 
 

 
 

 

 
 Fabricating inner wheel arch repair panel
Trial fitting new panel inside rear wheel arch

 
 

 

 
 
 Trial fitting outer wheel arch repair panel

 
 

 

 
 Outer panel is first tack welded in position.....
Then TIG welded... 

 
 

 

 
 The TIG seam is then planished and metal finished
until the repair is virtually invisible
 

 
 

 

 
 Left hand arch also needs extensive repair
 

 
 

 

 
 LH inner arch, with corroded sheet metal cut away
Trial fitting new rear boot floor assembly in conjunction
with outer wheel arch repair panels

 
 

 

 
 
 

 
 

 

 
 Fabricating a repair panel for the inner wheel well
Trial fitting repair panel in LH inner wheel well 

 
 

 

 
 Repair panel now TIG welded in place
Outer repair panel then tack welded in place 

 
 

 

 
 Seam then TIG welded
TIG weld then planished and metal finished 

 
 


Lots of progress in the CJ Coachworks....

 
 
 
 Fabricating a new footwell side panel
 

 
 
 
 

 

 
 New panel spot welded in place
A view of the new panel from the driver's footwell 

 
 
 
 

 

 
 Floors spot welded to inner sills
Wurth Body Wax is applied to all box sections
that will eventually be enclosed

 
 
 
 

 

 
 
 New outer sill spot welded to top edge of inner sill

 
 
 
 

 

 
 Spot welding lower frame anchor brackets in place
A view of the anchor brackets from the firewall side 

 
 
 
 

 

 
 
 New outer sill is spot welded to bottom of floor with
hundreds of welds

 
 
 
 

 

 
 TIG welding new jacking points to floor
 

 


Installing new floors in the CJ Coachworks....

 
 
   

 

 

 
   

 

 

 
   

 


Happy Birthday, Andre! Lots of progress in the Coachworks....

 
 
   

 

 

 
   

 

 

 
   

 

 

 
   

 

 

 
   
   
   

 
 

 

 


Starting to see the light at the end of the tunnel, now.

 
 
 
Unpacking your brand new bonnet
Almost ready to receive the new floors 

 
 
 

 

 
 
 

 
 
 

 

 
 Body wax sprayed inside reconstructed B pillar
 

 
 


Lots of progress in the Coachworks...

 
 
Entire rear panel is full of corrosion and will need extensive repairs
Also a lot of work required up inside left hand quarter
and B pillar
   
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
   
   

 


Cutting away corroded sheet metal, stripping shipping primer from new panels...

 
Cabin is braced at 8 points
Jake cutting out the old floor cross member

 

 

 
 
Shipping primer is stripped by hand from all new panels

 

 

 
Door skins and inner sill in bare metal
All new panels are sealed with epoxy primer

 
 


Total body restoration getting underway....

 
 
This previously "restored" did not look good after blasting
Media blasting revealed all sorts of horrors under the skin

 

 

 
   

 

 

 
 
Many panels are rivetted in place

 

 

 
B pillar full of corrosion
A pillars are no better

 

 

 
Our task is basically to build a new monocoque 
around the roof panel
Jake has a lot of cutting to do before he can start going
back with new sheet metal


Final assembly of your Stage One engine....

 
Balancing your crankshaft
 

 

 

 
 
Measuring deck height in order to calculate
precise compression ratio

 

 

 
 
Installing rebuilt head on short block
 

 
 



We have now completed the repair and rebuild of your cylinder head, and will be assembling the block next week.

 
Cross-hatch markings left on new cylinder walls
after the honing process
Cylinder head now completely rebuilt and assembled

 


I am pleased to report that Chris has now finished all of the machine work and porting to your cylinder head, and we saw some huge gains on the flow bench. We actually picked up more than 64 cfm on the intake runners, which represents a spectacular improvement in flow.

 
 
 How your cyl head deck used to look...
How it looks today 

 
 

 

 
 
 Using a sonic tester to measure wall thickness of 
intake runners

 
 

 

 
 Comparing your ported intake ports (right) with
a standard, unported head (left)
 

 
 

 

 
 
 You picked up 64.3 cfm - which is a spectacular gain!

 


The following sequence of photos show Chris rebuilding your IRS and Kevin doing your engine block machine work.

 
 
 
 

 
 
 

 

 
 
 

 
 
 

 

 
 Boring out the old sleeves
 

 
 
 

 

 
 Custom CJ top hat sleeves
Counterbore cut in block for new sleeve flange 

 
 
 

 

 
 CJ forged pistons
Honing cylinders to size 

 


I am pleased to report that we have now finished repairing all the various cracks and corroded areas on your cylinder head. It is a while since we have seen one that was quite this bad.

 
 
Repairing water jacket plug - step 1
Repairing water jacket plug - step 2

 

 

 
Repairing water jacket plug - step 3
Repairing water jacket plug - step 4

 

 

 
 
Re-shaping welded/repaired water jackets in deck surface
using an old head gasket as a template
 


We have our work cut out for us with this cylinder head rebuild. It really is in terrible shape and needs extensive weld repairs to deal with corrosion damage, stripped out threads, cracks and internal porosity issues. It has also had cam caps installed backwards, damaged cam saddles and is significantly warped.

 
 Water jacket plugs in top of head were stripped out
They will be welded up and have new threads cut 

 
 
 

 

 
 Head has obviously been welded in the past, although they
didn't bother to re-shape the combustion chambers
 There are a number of stripped out stud holes

 
 
 

 

 
 Water jackets on deck surface will be welded
and re-shaped on the mill
 

 
 
 

 

 
 Corrosion ground away from edges of water jackets prior
to welding
Darrell spent most of yesterday welding on your cylinder head 

 
 
 

 

 
 Base line flow testing prior to port work
 

 

 

 
 
Pressure testing identified porosity issues beneath
the deck surface (marked X)
 


Rebuilding front suspension, brakes, steering rack, steering column, etc. Pedal box has been converted to use upgraded brake master cylinder and booster from later 4.2 and V12 models.

 
Nickel plated front suspension components
Front suspension has been re-bushed

 

 

 
Vented front brake conversion
 

 

 

 
Upper steering column rebuilt
 

 

 

 
Steering rack has been rebuilt
CJ pedal box conversion incorporates 4.2 master 
cylinder and booster

 


Engine rebuild underway, body about to go out for media blasting...

 
 
 Engine has supposedly been rebuilt recently
 

 
 

 

 
 Removing the cylinder head
Timing chain frame is broken (see upper right) 

 
 

 

 
 Engine now completely disassembled
Water jackets blocked up with sludge 

 
 

 

 
 Body will be blasted back to bare metal
Disassembled bonnet and doors will also be blasted

 

 

 
 Everyone wants D Type wheels this month...
 


IRS rebuild underway, 438 items submitted for Nickel plating...

 
IRS rebuild underway
 

 

 

 
 
Mis-matched wishbones - note difference between inner
fulcrum ends marked A & B

 

 

 
438 items being submitted for Nickel plating
 

 

 

 
 
 
 

 


We now have your car completely disassembled and ready to be placed on one of the rotisserie jigs. As soon as one becomes available, we will start preparing the monocoque for media blasting.

 
 
 Engine and transmission have been removed
 Engine will be rebuilt to Stage One specs, trans will be 
replaced with a CJ5/600 five speed

 
 

 

 
 Repair panels have been rivetted into place on firewall
Most of the firewall will be replaced 

 
 

 

 
 Boot floor looks OK at first glance, but a lot of bondo
lurks beneath the white paint, so we'll see...
 All the numbers match throughout the car - engine,
transmission and body

 
 


I am pleased to report that your car has arrived safely at Classic Jaguar and we will have the restoration underway in the next few days!

 
 
 As found, nestling in Leander, Texas
 

 
 

 

 
 Engine has matching numbers
 

 
 

 

 
 Replacement panels appear to have been rivetted in place
 Mis-shaped boot floor rails suggest corrosion beneath
bondo and paint

 
 

 

 
 Car now at CJ - on the ramp to the Coachworks
 

Go to CJ Workshop