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 around 370HP and more than 400 ft/lbs of torque. The finished car will be among the fastest road legal E Types in the world. The car will be Dark Blue with Tan Suffolk & Turley hides.


Update report - May 5, 2022

Update report - April 26, 2022

Lots of progress with Jenvey fuel injection upgrade.

Another total Team CJ restoration wrapped up and ready to head home!

I am delighted to report that we are now well into the road testing phase of this project. So far the car is performing beautifully!

The starting point for this special restoration was a car that had already been very heavily modified and was something of a road legal racer. A previous restorer had installed V12 E Type flared rear arches but we decided to remove those and increase the width of the rear arches in a more subtle way.

The goal was to be able to put a wider wheel and tire beneath the rear, but to make it look like it could have been part of Malcolm Sayer's original design. You really have to look very closely before you notice that the rear wings are about an inch wider than stock, increasing the overall width of the car at the rear by a total of 2 inches. The extra space in the rear wheel wells allowed us to design a custom 7 inch wide CJ Borrani, to which we installed a 225/60 Avon radial. At the front of the car we are retaining the 6 inch CJ Borranis shod with a 205/70 Avon radials.

At the conclusion of this project we are planning a full professional photo shoot of this beautiful E Type.

Custom 7" CJ Borrani wheel, designed and built
especially for this project
Avon radials are a nice mix of period look
and modern performance

Road testing underway - this car is fast!
Note how the subtly modified rear wings allow
room for the wider wheel and 225/60 Avon

Dark Blue paintwork looks stunning outside

This photo shows the staggered wheels, 7" in the
rear and 6 inches up front

Chris Scarborough adjusting the camber between
test drives
Team CJ Stage 2 engine with milder cam option,
breathing through full Stage Two headers/exhaust

The engine and transmission have now been installed, maiden voyage just around the corner.

Gluing and clamping the cantrail chrome in place
Passenger door now installed

3 sets of hands needed to install the center
section of the headliner!

Rear bumpers and lights are now installed
Car is coming together very nicely!

Installing the under dash AC unit and assembling the bonnet.

Installing the under dash AC unit

Assembling the bonnet

Reassembly well underway in the main CJ Workshop.

Wiring the fuse boxes
Note electric power steering beneath column

Installing the minor gauge panel

The main body and doors have now been painted.

Gerardo has now painted the cabin area.

Painting the underside of the car.

Prior to sealing and painting, the Rocker Guard is

Underside of the floors now Dark Blue

Next to be painted will be the cabin area

I am delighted to report that earlier today Gerardo applied the first of the Dark Blue paint. First to be painted was the underside of the alloy bonnet, although the rest of the car will be painted over the next several days. Exciting times!

Top side of the bonnet masked off
Applying rocker guard in the wheel wells

I think the Dark Blue looks absolutely beautiful!
Note the slightly textured finish to the wheel arches

Lots more photos next week!

Oscar now has your chrome trial fit underway. Typically this process takes about a week to complete.

Fabricating new rear bumper studs
Oscar trial fitting your rear bumpers

I am pleased to report that we have now finished the bulk of the bodywork and the car has been primed with Raderal sprayable Polyester primer. We have also completed the IRS rebuild.

Bodywork has now been completed
Car has been primed with Raderal Polyester primer

IRS has been completely rebuilt

RBR vented brakes and remote bleeder system

Bonnet installation progressing well.

With the door and tailgate fit now perfected, it is now time to start fitting the new alloy bonnet.

Panel fit is beautiful throughout

Tailgate fits perfectly
Main body now sealed in epoxy primer

Time to start fitting the new alloy bonnet

Oscar has been busy skinning and fitting the doors.

Both doors are receiving new skings
After hammering over the new skins, Oscar then
used this machine to crimp them

The new skins were then spot welded in place

Bottom corner not quite square and will be built
up with a bead of weld

After grinding back the weld the corner is now
perfectly square

Time to fit the door

Restored door fits beautifully

Hector has now finished restoring and trimming your seats. He added some extra contour and side bolster support to the seat backs by carving and shaping additional foam padding during the trimming process.

Note extra foam padding to the bolsters
Carving the left bolster to provide additional contour
and support

Note how left bolster has now been sanded smooth

The finished result is subtle but provides
meaningful additional support

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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