1966 E Type FHC (ER)
Total restoration, ultra-high performance upgrades
Restoration log by Dan Mooney


 
 

 
Specification (briefly) for this project is as follows:

Total Team CJ restoration with ultra-high performance and reliability upgrades. The car will feature a Stage Two 4.7L engine rebuild producing 400HP and more than 430 ft/lbs of torque. The finished car will be among the fastest road legal E Types in the world.

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Update report - April 22, 2017

The guys in the trim room are busy restoring and trimming your seats.
































With the bulk of the sheet metal repairs and panel replacement completed at the rear of the car, Oscar has begun the lead loading process.



Lead loading welded seams beneath the
boot floor and rear quarters
























Factory lead removed and roof line weld exposed










Fresh lead applied to roof line welded seam
Lead loading around rear lamp areas











Oscar hand filing and shaping the lead











Preliminary trial fit of rear lamp housings




Oscar has been busy fabricating replacement panels for either side of the rear license plate panel and the (rear) inner wheel arch structures. Next up will be the discretely flared rear wheel arches.




















































































































The following photos show Oscar rust proofing and installing the outer sills.





Reconstruction of the trans and bell housing
side panels now complete










Firewall repairs completed, floors and trans
tunnel welded in place
























Trial fitting new outer sills























Inner sill box section will be rust proofed with Wurth
Body Wax prior to installing outer panels










Applying Body Wax to inner surface of outer sills
Wax also applied to inner sills






















Spot welding outer sills in place












With outer sills installed, next up is the new
boot floor assembly




The following sequence of photographs show Oscar welding the bell housing side panels, transmission side panels and lower side frame anchor brackets in position.




Spot welding the RH bell housing side panel
in position























Trial fitting the transmission side panels










Trimming floor opening to match shape of
transmission side panels












Plotting position of new engine side frame
lower anchor brackets











Welding new side frame brackets in place




Oscar has now spot welded the main floors into place, having first rust proofed all the inner box sections that would eventually be enclosed when the floor panels were installed.



Spot welding the additional inner sill gusset
in place












Rust proofing the main cross-member and up inside
the rear bulkhead










We have used Wurth Body Wax for more
than 20 years
Applying body wax inside rear bulkhead











View inside rear bulkhead










Spot welding left and right floors together
along the center line












Spot welding the floors to the drive shaft tunnel










Welding floors to the main cabin cross-member
And to the inner sills...










Several hundred spot welds now hold the floors and
inner sills together





Oscar has been hard at it since my last update, making excellent progress!





Separating bracing plate from rear of old
pedal box panel











Preparing to spot weld bracing plate to new panel











Welding new panel to body


































Trial fitting additional (third) inner sill gusset
Marking relief required to fit flush with inner sill



































Center transmission bulkhead cut away






















Preparing to weld new center transmission
bulkhead in place











Starting to fit bell housing side panels












Cutting away 'V12' flared wheel arches











Bump stop brackets will be removed










Rust commonly found behind bump stop brackets
Inner rear wheel arches are a bit of a mess










Lots of crude patching
Panel behind bump stop bracket had rust pin holes
so it will be cut away and replaced











Fabricating bump stop backing panel











Cutting away left hand inner wheel well























To be continued...




The following sequence of photographs follow Oscar's repairs and patching of the various damaged (and missing) panels in the firewall and beneath the dash. Not a particularly glamorous update, but essential repairs, nonetheless!



Several firewall panels required replacement
Newly fabricated repair panel on the left










The gaping hole this repair panel will fill
Trial fitting the new panel










Tack welding it in place












After metal finishing, the welds are invisible










Another repair panel being trial fitted












Another huge hole under the driver's side dash










Trial fitting a patch panel























Another large patch required beneath the dash











Trial fitting the patch panel












Repaired area metal finished and acid washed,
ready for priming




Oscar has been making fantastic progress in the Coachworks since my last update.




RH pedal box panel had been crudely repaired
in the past and will be replaced










Removing panel after drilling out spot welds
New panel waiting in the wings










Trial fitting new inner sills
























Trial fitting new floors























Wurth Body Wax sprayed beneath new
radius arm cups prior to installation










Acid washing bare metal inner box sections











All inner surfaces will be sealed with epoxy and
coated with Body Wax prior to installing floors























Sealer applied up inside A post towers
Trial fitting inner sill gussets










Old boot floor assembly cut away
























New bell housing side panels being trial fitted






















The first of thousands of spot welds!












We will use 3 inner sill support gussets per side











Underside of dash has been butchered!






















Central firewall also needs extensive repairs
Starting to fabricate repair panel for firewall




Oscar has begun the process of cutting away all the corroded sheet metal.



After stripping shipping primer from new panel,
future weld zones are carefully masked
New panels sealed with etching primer










Rebuilt body will feature additional inner
sill stiffening























Drilling out spot welds to remove floors












Floors and inner sills removed in one piece




Oscar placed your car on one of the roller-hoop jigs earlier today and has the body restoration underway.



The body will spend the next few weeks spinning
on one of the roller-hoop jigs
























Oscar has the sheet metal replacement underway
















The following sequence of photos show your powder coated IRS components, Nickel plated front suspension, and the finishing assembly of your Stage Two 4.7L engine. Unfortunately the oil pan that came in with your car was not serviceable so we will be restoring an alternative item from our used parts inventory.




































































We have now received your car back from the blaster. There are certainly some rough edges, but all in all not too bad...







There are several small rust holes in the footwells
and inner sills











Floors have several patches
Boot floor is rusted through










Several areas of the body have known violence
and pain in the past!
Both bonnet wings have been damaged
and patched











Difficult to imagine how damage like this
happened in the first place?










The firewall has a few areas that will need attantion











Patches to upper inner sill by data plate plinth
Some rust to deal with beneath passenger A pillar










More patches in inner sills
Wheel arch flares will be eliminated










Not the prettiest of welds...
Main bodyshell bathed in Ospho acid prior to being
sealed with epoxy primer




Your car has now been sent off to be media blasted back to bare metal and we expect to have it back in the next few days.



Bonnet was disassembled prior to blasting
Door skins were removed, revealing fairly rusty
inner frames











With outer sills cut away for access to the inner sills,
several patches were revealed











Boot floor looks pretty solid, although much of
it is covered with sound deadening material











Inner sills will obviously be replaced




After waiting patiently in the wings for 18 months, it is now time to get this very exciting project underway. The first task is to prepare the bodyshell for media blasting, which should place within the next few days. We also have the Stage Two engine well underway in the CJ engine machine shop.




Time to strip the car down for media blasting












All of the interior trim will be removed prior
to media blasting the shell























Old engine frames will be replaced










Outer sills will be cut away prior to blasting process
Shell now on one of the blasting rotisserie jigs










Engine rebuild will feature CJ Lightweight Stroker Kit
Special Trojan CJ valve guides bring F1
technology to this special build










Align honing cam saddles











Installing custom CJ valve seats
Trojan CJ guides installed after port work
has been completed










Honing guides for optimum stem to guide clearance
Machining 5 angles valve job










Front of head prior to cosmetic polishing
A little more presentable after sanding, polishing
and painting










Head ready for assembly
Note special bronze tappet guides,
relieved for high list cams











Head rebuild now complete, stroked block is next!




We are delighted to have this exciting project in the CJ Workshop and look forward to getting the restoration underway in the next few months.






 

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