1964 E Type roadster (AS)
Team CJ restoration


Specification (briefly) for this project is as follows:

Total restoration with Stage One engine, CJ5 five speed, Team CJ cooling, suspension and brakes, etc, etc.



The owners of this 64 roadster flew in to take delivery of their 'new' E Type and immediately set off on a 3000 mile road trip from Texas to Canada, via Southern California. Keep your fingers crossed for our intrepid travelers!
Bon Voyage!


More sounds....

Arm rests now re-trimmed and
Security cut-off switch hidden 
beneath steering column
Wiring and terminal for I-Pod

Your stereo CD/DVD?Sat Nav system has now been installed. I am pleased to report that the sound quality is outstanding (CD player). Click on the large photograph to see a video clip of the DVD screen opening up!


 Stereo head is a tight fit
inside stock 3.8 console
Sat Nav unit will live under
passenger seat
Antenna for Sat Nav. We couldn't bring 
ourselves to mount it on the dash
 Tweeters under corners of dash

Your CD - DVD - Satellite Navigation system arrived on Friday and we will be installing that for you early next week.

As you can see, we have now installed your new soft top boot. Tomorrow we will be installing the full tonneau cover.

Door handles and window winders
being installed
Radio console awaiting the arrival
of your stereo system!
Note red piping on the soft top boot
Flash makes the hide look lighter 
than it is

Tacking the rear edge into place
Using heat to remove wrinkles around 
the stitching for the zip-out window
Tonneau cover arrived this 
A lot of care was taken to obtain the best 
possible fit between window and top
cantrail seal

Trimming out the header bow, installing the top frame and trial fitting the new canvas top. Look for more photos tomorrow of the completed installation.

 Trimming out the header board
 Positioning the bows with
new webbing
 Pressing out major shipping wrinkles
New top features a zip 
out rear window
Trial fitting the new top

Time to restore the convertible top frame and install the new top, etc.
Installing and trimming out the
rear tack strip
Installing the re-trimmed
interior light panel
Painting the convertible
top frames
Trial fitting the restored frame

We investigated the possibility of using one of the factory dash switches to operate the heated seats, although that proved impossible due to electrical resistance issues. In the end we decided to install the switches discreetly beneath the dash (see below).

Note wiring for tweeters
Switch for heated seats
Installed discreetly under dash
Switch for heated passenger seat
New steering wheel looks good
 12 volt power outlet
Installed in the glove box


The following photographs show the seats actually being trimmed and the installation of the custom heated back and base pads.

 Padding seat back
Heat pad is held in place
with Teflon adhesive tape
 Wiring for heated pad is concealed 
at bottom of seat back
Gluing seat bottom covers 
 Installing seat bottom covers
 Note wiring for heated seats
Sam installing the passenger seat 
 V12 seats will be much more user 
friendly than original 3.8 buckets
Driver's seat goes into place 


Installing the underfelt, carpeting, moquette and hardura panels.


With the major road testing now completed, it is time to install your new interior. When you get a moment, please give me a call as I would like to discuss how we can best help you regarding the routing of any stereo related wiring. You may even be able to persuade me to install the stereo for you 

Wheels and tyres are a tight
squeeze in the rear arches
Dash top and chrome finishers
now installed
Screen pillar pads installed
We have installed stereo speaker cabling
to the centre console and both footwells

Update report - March 29, 2006

 Final nut and bolt, then into
the trim room
V12 seats now recovered 
 Dash top being trimmed
Custom heated seat bases 
 Trial fitting the restored dashtop


Over the last week we have been doing a lot of road testing and I am pleased to report that the car is running beautifully. As you can see from the photograph below, we have now installed the MSD 6AL ignition and it is working perfectly. Next stop the trim room!
Temporary seat and wheel used
for road testing
MSD installed
We set the rev limiter at 6000

Your dash panels have been trimmed out in red vinyl, per your request.

Having sourced a pair of V12 seats, we set about modifying the original 3.8 seat runners to work with the later model reclining seats and with a view to providing you with as much legroom as possible. I am pleased to report that we have succeeded in providing a lower than stock seating position with the absolute maximum possible rearward seat adjustment.
Screen was installed so we could assess 
eye level in relation to new seat base
3.8 seat rails were modified to
fit V12 seat bases
Adjuster arm was shortened
Seat now lower and further back
than stock 3.8 seats
V12 seats are also recliners


As you can see, we have now installed your rebuilt engine, CJ5 transmission, CJ headers, cooling system, rear bumpers and lights...and even the original California black plate.

As you can see, the doors and boot lid have now been installed and we have begun the installation of your new wiring harness.
Installing the Dynamat in
the cabin area
Gunmetal looks great in
the sun light
Installation of the new wiring
loom is already underway


As you can see, the bonnet is now painted and the car is having its front and rear suspension installed. Sorry some of my photographs are a little blurred!
 Trial fitting bumpers and
Holes had to be welded 
up and new holes drilled and 
tapped in the new bonnet
 New beefed up IRS
tie plate
 Installing the front engine frames
Grade 8 hardware thro'out 
Rebuilt IRS about to be
Installing replated front suspension 
On its rear wheels 
 Bonnet now painted
Gunmetal looks great! 


Yesterday we painted all the outer panels (except the bonnet) and I could not be more pleased with the finished result. The Opalescent Gunmetal looks truly stunning.

As you can see, we have now 'cut in' the cabin, the boot area and the underside of the floorpan. Because this car is likely to see a little track time, we gave it a little more 3M rocker guard protection than usual, especially behind the rear wheels/under the boot floor.

We are hoping to paint the outer panels by the end of the coming week. Watch this space!

Blue tape shows rocker guard
line under boot floor
Guillermo masking off the
3M rocker guard provides great
protection under the car
Extra rock guard coverage under 
boot floor
Cutting in cabin and boot
Extra rocker guard coverage hardly
noticable when painted


It has been a while since I updated this page - for which I apologise! As you can see, however, we have been making good progress with your car and should be applying the first of the Opalescent Gunmetal within the next few days.

The photos below show the car just after it received two good coats of the Evercoat Polyester Slicksand and a guide coat. The next stage will be blocking with 120 then 180 grit paper, followed by two coats of high build BASF Powerfill primer. That will then be sanded with 320 dry followed by 600 wet - at which point it will be time to apply the paint. Not long now!



The new bonnet has now been massaged into place and the majority of the lead loading has been completed along the side bulkhead and the upper sill line.


It is now time to install the new CJ engine frames and your new bonnet.

Lead loading around rear apron
Putting the car onto one of
the engine frame jigs
CJ engine frames, picture and
hinge frames installed
New bonnet trial fitted

Time for some lead loading. Click on the larger photograph to view a short video clip of Lawrence in action!


The following photographs show the installation of the outer sills as well as Lawrence fabricating and installing the LH outer bulkhead panel. We prefer to make this panel rather than use an aftermarket replacement as the available panels are shorter than we would like, and we make ours from heavier gauge steel which resists deformation from welding heat.

The yellow sustance you can see on the inner sill is Wurth Body Wax, which we apply to all inner panels and box sections during the course of CJ restorations.

Wurth Body Wax
Trial fitting out sill
This seam is also spot welded
Bulkhead (side) panels will
be fabricated
First the requisite contour
is formed
Next the flanges are formed
The flange around the curved
section is a little trickier
Another trial fitting...
 Once welded in place, the new
sheet metal is primed

More sheet metal progress....
Butchered driveshaft tunnel
had to go!
New section fabricated and
welded into place
The rear floors are generally
pretty solid....
Although they will need some
repair  before the new front 
floors can be installed
Section of rear apron was cut
out and replaced
Trial fitting the new
front floors
Spot welding the driver's floor
into place
Reaction plate and trans mount
must be trial fitted at this stage
With the new floors secured.....
It is time to trial fit the
new outer sills

Starting in with the bodywork....the short video clip below shows Lawrence making a repair panel for the rear apron to the side of the license plate panel.
 We are starting at the 
rear of the car
 This panel will obviously be
cut away
A replacement panel is
fabricated and trial fitted
 With the panel welded in place, we
trial fit the boot floor
Gas tank bracket is spot welded
into place
 Video Clip!
The planishing hammer leaves
a smooth and consistent curve
Spot welding the repair panel
into place
 Time to install the boot floor...
Trimming the boot floor priot
to installation
 Spot wedling the new floor
into place


As you can see, we have been busy rebuilding the IRS and your front suspension as your body waits its turn in the CJ Coachworks.
Rebuilding the differential
Suspension components have been
Nickel plated
Larger calipers installed
on the rear
Assembling the front suspension

More engine photographs together with a complete on-line Blue Print. The first two photographs demonstrate how much work was required in order to weld up and the cut and re-shape the water jackets on the underside of the cylinder head. I think it might be about as impressive a 'before and after' series of photographs as I have ever put on the webpage!

Click here for full engine specifications


 This is what your cylinder head
look like when we started
Today, after a great deal of work!
 30 cfm increase PLUS a
significant increase in velocity
 Cometic gasket brought compression
to the desired level
 Stage One Cams
ARP head studs 

As you know from our various telephone conversations, your engine really was in a sorry state! The cylinder head was not only very badly corroded but it was also severely warped. As you can see from the photographs below, all of the various problems have now been dealt with and the engine is now better than new!

This page will be updated as the engine goes together throughout the day.

Head was warped - off by 0.018"
Water jackets were very badly
Combustion chambers were pitted and
required extensive welding and re-shaping
Block will be re-sleeved after
Getting the block cleaning 
Items to be Nickel plated
Assembling pistons and upgraded rods
Measuring deck height to
calculate compression
Deck had to be welded
 Installing the pistons
Look for more updates 
throughout the day!
Off to the powder coaters..

Drilling out the spotwelds for
the front floors
We will fabricate a repair to the
tunnel, rather than replacing it
Removing the firewall
kick panel

Time to start the sheet metal and panel replacement....
Timing chain cover will be
Last few bits of rusty metal are
cut away
 Drilling out spot welds and removing 
remainder of outer sills
Your new bonnet is in the crate
in the background
Cutting out the old boot floor


Gathering some of the new parts for your Stage One cylinder head
(just waiting for new seats)

The following photographs show the car being primed earlier today. The also show why you really have to install new engine frames. The problem is they rust from the inside out. You can see below how an apparently innocuous pin hole is only the tip of the iceburg. Tapping the metal surrounding the pin hole with a blunt, lightweight awl gave a clear indication of the internal condition of your frames.
Screw hole in one frame
X marks an a small rust hole
Tapping with an awl
Pin hole marks weak point 
in frame
You can see he rust inside this hole...
This is STILL only the tip of
the proverbial iceburg

As you can see, we have now had the car bead blasted and disassembled the last of the mechanical components. No huge surprises after the blasting process, although we obviously have a fair amount of sheet metal replacement ahead of us.
 IRS disassembled
Back from the blasters! 
Bootlid excellent 
 Doors almost as good!
Inner sills surface rusted 
Outer sills (inside out)
 New boot floor required...
The car was in a knife fight (and
apparently lost!)
 New treatment recently
introduced in CJ Coachworks
DP90 epoxy primer applied
immediately after DX1791

Block now completely stripped
Front of head was cleaned and...
Major pits sanded out prior
to machinework

As you can see, the car came apart without any drama, although the engine is one of the grungiest we have come across in a while! The head has suffered some significant corrosion damage and will need some additional welding, although there really isn't anything to worry about. It was most unusual to find the lower half of the oil dipstick snapped off inside the oil pan!
 Car now completely apart...
Note snapped off dipstick in
the oil pan!
Some of the head studs are 
corroded solid 
Cyl head is a bit of a state! 
Mains, rods and pistons are
all factory standard sizes

Main floors are exceptionally
Boot floor has had some
untidy pop-rivetted repairs
Trans tunnel has been cut away
from the main floor!
 Engine and trans removed...
IRS about to be dropped out


The restoration is underway! We have already set aside a new bonnet for your project, as well as new bonnet hinge and picture frames. The jury is still out on the engine side frames....
Starting to come apart...
Bonnet hinge frame has
been badly bashed about
Trans tunnel has also had
its share of pain
Picture frame needs replacing
Note lower section of picture
frame in this photograph
Main and boot floors appear
to be very sound

I am delighted to report that you car has arrived safely at Classic Jaguar and we will be getting the restoration underway in the next few days. I hope you enjoy watching the car come together over the coming months!


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