1956 XK 140MC roadster (BK) 
Driver restoration


Specification (briefly) for this project is as follows:

Remove body from chassis, totally restore body and replace on restored rolling chassis being prepared by owner.


I am delighted to report that the car is now totally finished. It runs and drives as well as it looks and is ready for your collection. Bill, it has been our absolute pleasure to build this beautiful car for you and Denise. Thank you both for your business and also for the kindness you have shown towards Evan and Earl.
Dan Mooney
Team CJ

It's time for the old car to move under its own steam once again! It has taken well over a year to get the car to this point. Click on the photograph below to see a video clip of Sam test driving your car earlier this morning.


Rear bumpers installed
Crash roll finished
Door pockets and panels
trimmed and installed

Time to start putting the interior in, Bill!

The cylinder head is now installed and the engine running beautifully. Click on the photograph below for a brief video clip of the initial test firing!

I am pleased to report that we have now finished the cylinder head rebuild. Harold did a beautiful job, including a five angled valve job (4 machine, one finished by hand). It shouldn't be long before we have it reinstalled and get your engine running!

Unfortunately, the news is not good today, Bill. As we were running through our check list prior to firing up your engine, we found that you had no compression in two cylinders. We went on to perform a leakdown test and found that two of your intake valves were not sealing at all. We pulled the valve covers and found huge inconsistencies in your valve lash and, much worse than that, your cam caps had been incorrectly installed and ALL of your valves had been clashing (intake against exhaust) thanks to badly adjusted cam timing.

Bottom line is that your cylinder head was a bit of a disaster area, I'm afraid. Needless to say, we have a full cylinder head rebuild underway!.

Cylinder head is a bit
of a disaster area
At least two valves were
badly bent
Cam caps were all
jumbled up
Cleaning deposits off the 
piston tops while we have access
We will use a composite
head gasket

The guys in the workshop tell me that by this evening they will have run out of excuses for not firing up the engine!

The dash has now been retrimmed and all the rebuilt gauges installed...

Getting very close to firing her up and setting off on the maiden voyage! Unfortunately, much of the work over the last couple of weeks has been underneath, so not too many good photo opportunities lately!
Time to put the car
up in the air
View inside front wheel
Car as clean underneath
as it is up top!
Rear hubs and brakes
rebuilt and installed
Installing rear bumper

More progress.....
Wiring in the rear lamps
Boot furniture being
 Installing the front bumper
Installing front lamps

Many thanks to you and Denise for your generous donation towards the car we are building for Sam's kids. Your kindness is much appreciated by the whole team.

As you can see, John has been making great progress and the car is going together very well.

 Installing new CJ radiator
Rebuilt carbs installed 
Wilwood upgrade 
The bumpers are back from
the platers and look superb

It is time to start bolting the old car back together!

I am pleased to report that the final painting session went very well and that the body went back on the chassis without a hitch. Mike and Lawrence have been busy installing the doors, bonnet and boot lid, all of which fit beautifully.

Although normally painted body colour, we decided to leave the new hinges cad plated.

Body wax inside head and
indicator lamp pods
Note bonnet fit
New hinges
Installing the doors...
With seals and latches...
Check out the panel fit

At this stage we have painted all the sheet metal on the interior of the bodyshell, as well as the engine bay and the underside of the tub and all the various panels. The outer body currently only has one coat of Old English White and will receive its remaining 3 coats once the body has been reunited with the chassis and we have been able to re-check all our panel fit, etc.

We will be installing the body on the chassis tomorrow morning, with a view to finishing all the paintwork on Monday.


Time for some Old English White...
 Door latch mechanism
Door mechanisms restored 
Boot latch mechanism 
The painting process underway 

Trial fitting all the chrome as your XK edges closer and closer to the CJ paint booth!

Lawrence worked on your car right up to the evening before he went in for his shoulder surgery on Thursday. It is now ready for high build primer (PPG 271), afterwhich he will sand it with 320 (dry), 620 (wet) - then it will be painted. He will not be returning to work until Monday, April 7, but rest assured your car will be Old English White very soon thereafter.

I thought you might like to see some photographs of John Claydon installing your new CJ5/XK five speed, as well as your Team CJ flywheel, etc. Unfortunately not much can happen now until Lawrence returns to work.

Lawrence has been blocking on
your car solidly for 2 weeks
Original damaged flywheel
Installing new pilot bushing
CJ5/XK adaptor plate and
clutch disc
Unusual view of bare XK chassis
Installing CJ5/XK plate
to your bellhousing
New 12lb Team CJ flywheel
New clutch installed
Beautiful panel fit
Fine tuning bonnet fit during
blocking process - it is now perfect
CJ5/XK installed

The next three weeks will be spent constantly sanding and blocking your car in preparation for paint. It is difficult to capture on film the progress that Lawrence is making, but time spent during this vital stage will result in the bullet straight body and perfect panel gaps we strive for in all our restorations.
Welding up antenna holes....
on both rear wings
Check front wing for straightness
in relation to the door skin..
Boot lid is blocked in conjunction
with the surrounding panels

It was good to see you last week when you visited to check on the progress. As you can see from the following photographs, things are moving ahead in leaps and bounds!
 Interior is meticulously sanded
and acid washed
 A dirty job, but....
Somebody's got to do it!
 Ready for epoxy primer
John removing your carbs
for rebuilding
Off to the dumpster - old
sheet metal
Ready to move through to 
the booth 
The whole car is sealed with
DP90 primer
Including inside the engine bay 
Carbs removed 
Inner wing supports rusty 
Frabricating new pieces 
Starting to look like a car again.. 

Lawrence couldn't make it in through the ice storms today, so the following photographs show his efforts yesterday.
Acid washing the inner wings
Priming with epoxy primer
Likewise on the opposite side
We were able to do an
'invisible mend' on your broken grill
Priming the rear deck

RH side pod reinstalled
Note lead work
Great fit on driver's door
We think we can weld your cracked grill, 
although pot metal is tricky
Lead loading the RH pod
Almost there...
Finished! No more welding!

New A post shut panel welded
into place
Installing the door to match up with
repaired wing
Lead loading the welded seam between
the cowl and the repaired wing
Note how well the new sheet metal in the
front wing lines up with the door

The left hand front wing has/had bad collision and corrosion damage and the only proper way to repair it is with new sheet metal. The following sequence of photographs show Lawrence making replacement panels for your car using nothing more than flat steel, an English wheel and a great deal of very noisy hammering!

I thought you might find it interesting to see the entire process from start to finish.

Blasting revealed problems with
the RH front wing
Usual corrosion under side lamps
Bottom of wing rotten
This was disguised with bondo
Marking out the area to be
cut away/replaced
Measure twice, cut once....
Making a card template for
the new wing
New sheet metal and English wheel
Forming the bottom edge of the 
new wing
The bottom corner taking shape
Installing rod to form bottom
edge beading
What it looks like inside - very
Trial fitting the repair panel
 Cutting out vent flap
Offering the old vent flap
surround into place
Welded in place
The wing must be temporarily installed
to ensure good shut lines
Then removed again to welded
along the internal seam
Grinding away excess weld
 Spot welding along the interanl
Spot welding the repair panel
along the entire seam
Close up of joint between old
and new sheet metal
 Correcting any distortion caused
by the spot welder
Starting to look like something! 
Lead is then applied to the seam
Applyling lead along the upper weld
Filing away excess lead

Lead loading the seam between the cowl and the repaired right hand wing.
 The lead loading process begins
Then a file to remove any excess 

It took lots of hammering to
reshape the wing
B pillar finished
Out with the old, in with the new
More rust proofing prior to
fitting front wing
This shot shows the bottom edge
of the door - not straight
Inner wing now pristine
Welding the wing back where
it belongs

Update report - February 2, 2003
Steady progress this week as the reconstruction of the boot compartment and the repair of the rear wings is completed.
Fabricating new rear apron
Welding apron in place
Repairing lower LH wing
Bottom of rear wing cut away
Fabricating and installing
boot floor support rails
Lawrence signs every car
he works on!
Making progress!
Invisible mending...
Moving to RH rear wing

Those of you that follow our work in the Team CJ Coachworks will already know by now that we rust proof any and all inner cavities and enlosed box sections during the course of our body restorations. In the following sequence of photographs, you can see Lawrence applying Wurth Body Wax to the inner surfaces of the boot side panels - a notorious rust trap. Not perhaps the most glamerous photos, but a crucial (and often overlooked) aspect of any true restoration.

Wurth Body Wax...
is applied to all enclosed
Trial fitting new panel
Lower boot floor replaced
More new sheet metal!
Trial fitting spare cover

More progress as Lawrence starts piecing your car back together, one fabricated panel at a time!
New floors made from
Only the drive shaft
tunnel is original
Wurth bodywax om B pillar
and inner firewall
Top of B post built up
with lead
To match door height
Boot was a disaster
But no problem to Lawrence
Making new sides panels
for boot repair
Panels being welded in place
This panel had to be fabricated

Entirely new upper left
Note new sheet metal
box sections
View of LH A pillar and
Fabricating and trial
fitting new shut face panel
Fabricating new B post 

I am delighted to report that Lawrence is now well on the road to recovery (following his car accident last November) and has finally returned to work. His first priority is to finish the restoration of your XK140 and as you can see from the following photographs, he already has the project well underway!

Look for frequent updates in respect of this particular project over the coming weeks!

Fabricating new LH
firewall panel
Fabricating and installing new
RH B post assembly
Test fitting RH door

As you can see, we now have the body restoration well underway. Our starting point will be the new box section sill(s) that Lawrence made for you. He is also going to have to fabricate a new firewall and lots of other good stuff along the way!
Reconstruction surgery begins...
Note new box section sill...
The view from what will be the footwell...
New firewall section frabricated...
Inner sills made from scratch...

Lawrence has been beavering away on the body and chassis for you and I am pleased to report that we now have the body on a roll around jig and awaiting its turn at the bead blasters.
 First the wings are removed
 Front and rear
Gas tank is rusty and will be replaced
The box sills are very rusty 
Factory leaded seam is point wyhere
front wings are cut off
Almost there....
More rust 
Body lifted clear of chassis 
Not much left! 
Everything will be stripped to bare metal 
Bonnet is aluminium 
It will be transported on one of our 
purpose built jigs 

Return to Team CJ Workshop