1966 E Type FHC (Jim)
CJ driver restoration


Specification (briefly) for this project is as follows:

Another driver CJ restoration to be finished in black with red Suffolk & Turley hides and some subtle Team CJ performance and reliability upgrades, including a CJ5 transmission, uprated brakes, cooling, ignition, suspension, etc.



Customer update - October 2016

Dear Dan,

I am attaching a photo of my Jag I took today showing the successive first place victories in the Delaware Valley Jaguar Club's annual sanctioned JCNA Concours. I received my Jag from you in August of 2010, too late to enter the Concours that year. For the next four years I have taken first place until this year when I decided not to enter the competition, but just show the car. 

As I mentioned, this is not a trailer queen. I drive this car every weekend except when there is inclement weather, putting on about 1500 miles each year. All the senior members of the club are aware of the spectacular nature of this rebuild and the owner of one of the top east coast Jaguar repair shops, who actually races E Types, said to me "This is the way Jaguar should have built these cars."  The accolades are for you and the team at Classic Jaguar.

Please extend my best wishes to Andy, and to Carlos, who did such a spectacular job on the 100% leather interior. 

Jim Cassano

Customer update - June 2011

Dear Dan,

I'm sure that all of you will be pleased to know that my E Type won best in class at this past weekend's Delaware Valley Jaguar Club's JCNA sanctioned Concours D'Elegance. According to the judges, no one else came close to my car. There were 25 E Types entered in the Concours event.

Yesterday, the Club also had an "E Type Extravaganza", where 40 E Types gathered together and went on a cross-country tour. At this event, two of the judges from the prior day Concours told me that mine was the car that Jaguar should have built and was hands down, the best of the bunch. You should be proud as well.

I am attaching the "mirror" picture to the one on my CJ restoration blog where I am standing today in the same pose as I was in 42 years ago when I owned my first black/red E Type!

Jim Cassano


Closing report - July 23, 2010

I am delighted to report that your car is now ready for collection and will be headed in your direction later today!














Your custom four outlet exhaust installed....



We have now completed the interior installation with the exception of the center and radio consoles, and the passenger seat. We will install those items once we have finished the mechanical shakedown - which will be underway during the coming week.

 Time to install the luggage 
rail runners
Carlos uses a laser to ensure that the runners
from each panel all line up perfectly

 Rear compartment starting to 
take shape

Rubber inserts now installed


Carlos fabricating and trimming new visors for your car...



New rear boot boards have been fabricated and trimmed out in red hide, heated rear window installed...



Time for the final push on this project. This car should be heading northward in the next few weeks!

Seats have now been restored
and retrimmed
Trimming center console in hide

One hinge cover was rusted so Darrell 
fabricated you a new one





Although we are still waiting for delivery of your custom four outlet exhaust system, we couldn't resist having a quick drive around the CJ carpark anyway! Click on the photo below for a short video clip of your car's maiden voyage.


Your engine bay filling up rapidly, we should be firing up the car in the next day or so.

CJ headers installed
Delco alternator, billet pulleys
New gas tank installed


I thought you might be interested to see the tail housing for your brand new CJ5 transmission. CNC machined from a single billet of aluminum, it seems a shame that it will be hidden beneath your car.



Running the rebuilt engine and tuning your carbs on the engine test rig. I am pleased to report that the engine passed all tests with flying colors!



We have now received all your chrome back from the platers and have started the installation process. Your engine (short block) is completely rebuilt and we just flow tested your ported cylinder head this morning (see flow sheets below). We picked up 38 cfm on the intake side, which represents an exceptional gain.

This is what $8k worth of chrome plating 
looks like - ouch
Installing bumbers and lights
Base line flow numbers, before
port work
We picked up 38 cfm
Carbs now completely rebuilt
Short block now assembled
Assembling and installing the windows

Progress in both the machine shop and the CJ workshop...

Boring out the old sleeves
Honing the new cylinders
Preparing to surface the block

Forged Venolia pistons
Installing the restored dash panels

Restoring your dash and gauges..
These gauges will be sent off
to be rebuilt
Center dash was rough
Starting to look much better!
Mechanical oil pressure gauge is
a nice upgrade

Engine rebuild in progress...

Tearing down the engine block
It was pretty grimy!
Corroded water jackets were first
ground back
A bead of weld was laid around each 
of the damaged water jackets
Water jackets will be reshaped on the mill
Uprated rear crank seal


We are pleased to have this car back in the schedule and will get the ball rolling with a Stage One engine rebuild.

Matching # cyl head
Water jackets will need to be
welded up and reshaped
Head pressure tested OK
New custom S&T interior
kit has now arrived

Going back together with the front suspension and steering, etc.


Carlos buffing the newly painted body
Dynamat installed thro'out the cabin
Engine frames now installed

More black paint....

 Interior and underside carefully masked
Starting to apply the base coat 
 Paint looks great outside in
the sunshine
 Seriously grimy IRS!

More black paint!


I am pleased to report that we have now applied the first of the black paint!

Trial fitting bumpers and lights
Getting ready to paint the underside
Seam sealer is applied to all seams 
and joints
Including up inside the wheel arches
Floor  sealed in epoxy primer
3M rocker guard is then applied
The underside is now painted black
Better than new!

With all of the blocking now complete, your car has been put in high build primer. Look for it to start turning black in the next couple of weeks!


The bodywork has now been completed on this car and the Slick Sand has been applied.

I am pleased to report that your car is now on one of the frame jigs and the bonnet fitting process is underway.

Tail gate now fits beautifully
Installing the engine frames
Time to start the bonnet
fitting process

Installing the new boot floor assembly, inner rear wheel arches and license plate surround panels.

Trial fitting/trimming new RH 
inner wheel arch
The new panel is then blasted 
and primed
 Installing the new license plate 



Repairing the rear wings....

New repair panel is shaped for contour 
then trial fitted and trimmed
New sheet metal is TIG welded
into place
Corroded inner skin has been cut
away. Bare metal is sealed......
Coated with Wurth Body Wax
 Inner repair panel was
 Inner repair panel welded into


Installing the new floors, skinning doors, etc..

Inner sill support gussets are spot
welded into place
New lower subframe mounting
brackets installed
Trial fitting sill end closing panel
over subframe mounting brackets

Trial fitting new floors
Afte a little trimming, they fit
Inner sills are coated with Wurth
Body Wax

More wax applied to inner box sections of
rear bulkhead and cross-member
Radius arm anchors are rivetted
into place
Hundreds and hundreds of spot 

Rear brace finishes off 
installation of the new floors
Fitting a new door skin

 Trial fitting the re-skinned door

Installing new inner sills, etc...
Old inner sills and cross-member
were left in place until now
New RH inner sill was first
to be installed
Cutting out the old cross-member and
RH trans tunnel panel
Bound for the dumpster
Installing new trans tunnel panel
Trial fitting new cross-mmber
Tunnel and cross-member are
spot welded into place
Almost ready for the new floors


Assembling the restored bonnet.


The following photos show Darrell repairing the bonnet center section as well as most of the replacement panels that will be used when we start the restoration of the monocoque next week.

First the repair panel is tack (MIG)
welded into place
It is then TIG welded along the seam
 Good as new!
Top of the bonnet mouth req'd
a little massaging
 Pulling out a couple of small dents
 Years ago, someone apparently put some 
lead on top of rust..
The problem starts to become
apparent as lead is melted

 A rusty panel and some ugly
old welds
 Shaping the replacement panel
 Newly fabricated panel is a
perfect fit
The seam is then TIG welded.... 

 A perfect repair
A clue to what is coming


We now have the body and all the various panels back from the media blasters. After a thorough cleaning we sealed the bare metal in BASF etching primer. While the body was away we have been busy repairing the bonnet and we will have the panel replacement underway in earnest in the next couple of days.

Lower edge of RH front wing being
Repair panel was fabricated and
TIG welded into place
Both front wings are now
as good as new
Leading edge of bonnet center section 
also received new sheet metal
Back from the blasters, full extent
of rust now clearly visible
Both rear arches will be replaced
Rear bulkhead and upper floors
are sound
One side of trans tunnel will
be replacd
Door skins were cut away prior
to blasting
All the bare metal was immediately
sealed with etching primer
Floor cross-member will be replaced
Unusual view up inside one
of the A post structures
Firewall is sound

Sheet metal repairs on the bonnet while the main bodyshell is at the blasters.

Denise Cole has complained that I only 
ever photograph her son from the rear...
So here he is, Denise 
 Bare metal has been acid washed
 Bonnet will need only minor repairs
Conversely, the body will require major
panel replacement!
 Off to the blasters...


The following photographs show Darrell cutting out the floors and the outer sills prior to sand blasting. (No point paying the sand blaster to strip panels we know we are going to replace).



Time to get this project underway in earnest. Once the car has been completely disassembled, it will be placed on one of the rotisserie jigs and sent for blasting. Watch this space!

People have cars built for all sorts of different reasons. In this case, Jim has fond memories of the 67 E Type that he shared with his late wife, Lin, back in the sixties. That car was sold to finance Jim's MBA, despite Lin's protestations that they should keep the Jaguar and sell the Mustang they also owned at the time. She apparently loved the E Type, driving it to the high school where she taught  - and where she must have been a hit with all the students!

Although Lin sadly passed away four years ago, you just know she would have approved of the car we are building for Jim

1967 FHC that Jim wishes he
had never sold....
One cool school teacher, circa 1969
Jim will repeat this pose when we
have his 66 FHC ready for him


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