Jaguar 420 (WB)
Major mechanical overhaul, Suffolk & Turley interior
|Restoration Log by Dan Mooney
The door casings have now been trimmed and Carlos is about to turn his attention to trimming the rear seat.
We have now completed the sanding and buffing process and I am pleased to report that we were able to dramatically improve the appearance of the old paintwork, eliminating the majority of the shrinkage issues and severe orange peel texture evident in the old clear coat. Carlos has now begun trimming the door casings.
Restoring the seat frames and installing the new wool headliner.
|Seat frames have been blasted and powder
|Frames now reassembled and ready for
|Earlier today Carlos finished installing
new wool headliner material
Carlos has now begun the process of installing the new wool headliner. When he returns from vacation in a little over a week he will trim the seats and begin the process of installing the new Suffolk & Turley interior.
|Rear screen surround panels were damaged
|We fabricated new panels from aluminum
|Carlos has been trimming the various
panels in new grey wool cloth
|Sanding and polishing the center gauge
Stripping and preparing the seat frames for trimming.
|Front seats stripped to their bare frames
||New burlap material will be applied to the
|Almost ready for the cushings
The restoration of the interior wood is now virtually complete. We have another couple of coats of clear to apply before each element can be sanded and buffed to a high gloss finish. We are about to start installing the Suffolk & Turley interior and have already stripped the cabin and installed Dynamat throughout. Removing the old underfelt and glue revealed pristine, totally rust free floors.
|Scraping away all the old glue and
revealed pristine sheet metal beneath
|Applying Dynamat throughout the cabin
||New veneers sanded and ready for final
|Applying the first of several coats of
||Several coats will be applied then sanded
buffed to a high gloss
The following sequence of photographs show how Jason applies the beautiful European Walnut veneer to the main dash panels, beginning with the central minor gauge panel.
|Preparing to apply veneer to the minor
||Special veneer tape is used on the front
|4 pieces of book ended veneer will be used
center gauge panel
|Rear side of the veneer sections are
|Sanding the veneer before the gluing
|Removing old veneer from the panel
|Cutting relief slits for the gauges and
|Applying the special veneer glue
||After gluing and taping, the panel is
placed in a
vacuum press and left for about 6 hours
|Removing the veneer tape
|Using a chisel to remove veneer tape from
the front side of the panel
|Selecting the best veneers for the main
glove box panels
|An important part of the process as it's
neighboring panels complement each other
|Minor gauge panel almost ready for sanding
|Now to repeat the process with the main
and glove box panels
|Main gauge and glove box panels in the
It is now time to start the process of applying the burl walnut veneer to the interior wood elements. The veneers are first treated with a special softener, before being pressed flat for around 24 hours. The veneers, which are by now noticeably flatter and more flexible, are then "book ended" in order to produce one continuous burl pattern throughout the width of each piece of trim.
|The veneers are treated with a special
||With the softening agent applied, you can
start to get
an idea what the finished veneer will look like
|Book ending the veneers to provide one
burl pattern for the longer trim pieces
|Selecting the best veneers for each trim
||6 book ended veneers will be used for the
above the side windows
Jason has been busy stripping all the old stain and varnish from the interior wood trim pieces. Initially this is done with paint stripper, lacquer thinner, Scotchbrite pads and elbow grease. Once the wood is stripped, it is then sanded with 320 grit, soaked in water to raise the grain, then sanded again with 400 grit.
|Trim will require several repairs
|Damaged veneer in the RH cantrail
It is now time for us to remove and restore all of the interior wood trim. Some of the veneers have been damaged over time so we have chosen some very special European Bur Walnut veneer that will be matched, book-ended and applied to each of the trim pieces.
|All of the interior wood trim has now been
|European Bur Walnut will look absolutely
beautiful inside the Jaguar's cabin
I am pleased to report that your rebuilt front and rear suspension has now been installed, as has your rebuilt engine. The AC installation is progressing well and the car has now been converted from steel disc to wire wheels.
I am pleased to report that we have now completed your engine rebuild.
|Machined block washed down and ready for
|Valve covers and crankcase breather have
repaired and machine polished
|Installing the crankshaft
||Installing the timing chains
|Cylinder head now fully assembled
||Setting valve lash on the Stage One cams
|New timing chain cover was required
|Tappet guide hold down kit has been
on the exhaust side of the head
|Polished valve covers add the finishing
The front suspension and brakes have now been completely rebuilt, restored and installed back beneath the car. The rear suspension and brakes have been serviced and the IRS will be reinstalled early next week. Your engine rebuild is progressing nicely in the CJ machine shop.
|Main bearing housings after completion of
the align hone
|Measuring main bearings in order to
requisite crank journal sizing
|Torque plate cylinder hone in progress
||Original timing chain cover was damaged
repair, so a new cover will be used
|IRS tie plate also in poor shape
||New billet alloy IRS tie plate installed
|New output shaft seals, bronze fulcrum
rebuilt brakes, new springs and Koni shocks
|Fabricating new brake lines
|Front suspension and brakes completely
||Rebuilt front suspension subframe now
beneath the car
We have now completed your Stage One cylinder head rebuild and have the block machine work well underway.
|Block on the floating boring bar to
machine out old sleeves
|Note water jackets behind sleeves
|Cylinder head has now been machined
|Stage One head rebuild completed
|Front subframe blasted and powder coated
We now have your engine rebuild well underway, with the Stage One cylinder head rebuild scheduled to be completed by the end of this week.
|Engine as received in the CJ machine shop
||Removing the cylinder head
|Tearing the cylinder head down on the bench
|Valve seats were in very poor shape
||We surfaced both exhaust and intake flanges
|View along one of the intake runners after
|Pressure testing the head
||Installing tappet hold down kit
|Front of head prior to sanding and
I am pleased to report that we now have this project underway. Our first task is to remove the engine, transmission and front suspension.