Job # 1969 (SC) - Jaguar 3.8 E Type Stage One engine and IRS rebuild

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Putting the finishing touches to this special engine...

Preparing to assemble the cylinder head	Head on the assembly bench
About to install the cylinder head
	One of the prettiest engines in the automotive world

The short block has now been built and all of the machine work completed on the cylinder head. All that remains is to assemble the head and reunite it with the block.

Balancing crank	Mock up of installed piston to calculate deck height for precise compression ratio
Surfacing engine block with new timing cover	Block ready for assembly
Short block now fully assembled	Cylinder head painted Pumpkin Gold

Lots of progress in the CJ machine shop....

Flow testing cyl head after porting	Coated CJ pistons
Intake side after porting	Exhaust side after porting
Pressure testing Blackwell manifold after porting	Manifold has been polished

I am pleased to report that your rebuilt IRS is being collected on Monday (2/14).

Align hone completed....

We have now installed all the new top hat sleeves and have also machined the block for upgraded freeze plugs.

First three top hat sleeves now installed	Boring for last three
Machining freeze plug holes for upgraded plugs	Video clip of freeze plug hole machining

Lots of progress in the machine shop...

Machining flanges for top hat sleeves
Ported intake runner	Venturi size set, valve job blending
	Pressure testing after porting

One slight problem we ran into during the port matching stage was the size and shape of the runners on the Blackwell intake manifold. They are already larger than we would prefer, and a long way from being perfectly round. As we really don't want those ports any larger, we decided to match the cylinder head intake ports to the size (and slightly irregular shape) of the manifold.

Click here for a video clip of Chris explaining this process

Matching size and shape of intake ports to Blackwell manifold

Installing custom CJ seats, cutting out old cylinder liners....

	Old sleeves now removed, water jackets were blocked
Sizing pockets for custom CJ seats	New CJ seats installed
Trial fitting TWM throttle bodies to manifold	Throttle bodies will be port matched to intake runners

As this engine will be fuel injected, we are building it to 10.5:1. We will achieve this with a custom set of forged CJ pistons with an increased dome volume. The second photo below shows a mold of the combustion chamber that we made for Ross, so that they could design the dome and maintain adequate piston to valve clearance. These particular pistons will be ceramic coated on the top and Teflon coated on the skirts.

Base line flow testing in progress	Combustion chamber mold assists with piston to valve clearance calculations
Old liners about to be machined out	Pressure testing cylinder head - passed.
Base line flow test results

Some interesting background information on your Blackwell manifold. My thanks to Doug Buchan for forwarding the article earlier today.

I am pleased to report that we have now completed your IRS rebuild....

I am pleased to report that your engine and IRS assembly arrived safely at CJ and we have both rebuilds underway.