4.2 S1 E Type Jaguar - Job # 1922 Full engine and IRS rebuild

Specification (briefly) for this project is as follows: Full engine and IRS rebuild

IRS now ready for final assembly...

Diff casing has been painted with red Glyptal	Installing new shocks onto CJ  springs
Installing re-sleeved and Nickel  plated calipers

Align hone in progress....

I am pleased to report that we have your engine and IRS rebuilds well underway. Unfortunately, your IRS is probably the worst we have ever seen in terms of condition. We enjoy a challenge, but this thing was really nasty!

The engine has obviously been serviced a number of times. The rod journals have already been ground .030" undersize, so we were fortunate to track down some .040" rod bearings in the UK. The water jackets behind the cylinder liners were completely blocked with rusty sludge so the block required some significant extra time in the chemical wash tank. We have already replaced all the liners and begun honing the cylinders to size.

Engine as delivered		Block torn down
	Cutting out old liners on  boring bar	Water jackets behind liners were 100% blocked
With new top hat liners installed, block is surfaced	Valve covers are cracked and require welding
Drain plug hole will be welded up and re-cut on the mill
Honing cylinders to size	IRS may be the nastiest one we have ever seen!
Someone's first attempt at welding, perhaps (marked X)	Handbrake mechanism rusted and seized solid	IRS items cleaned and powder  coated
One hub carrier badly damaged and had to be replaced	Rear splined hubs also had to be replaced	Differential now rebuilt