1965 E Type roadster (OS) Stage One (rolling chassis) restoration

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Specification (briefly) for this project is as follows: Total restoration to rolling chassis stage. Coachwork to be refinished in Opalescent Dark Blue.

I am pleased to report that your E Type is homeward bound! It is now time for you to put your own finishing touches to this beautiful roadster. Many thanks and best wishes from all of us at Classic Jaguar!

Installing your new canvas convertible top...

	The view from within!

Installing the convertible top frame....

We have been busy installing those parts of the interior trim which have to be in plac before we can install the convertible top - something which should be completed early next week. Per your instructions, we have not installed any Dynamat on the rear bulkhead.

	Installing the Dynamat
Installing the moquette	Both sills now trimmed out

Installing the front bumpers....

It is time for the final push to finish our part of the project and get your car back to you so that you can get her ready for the show circuit! During the coming week we will be installing the Dynamat, front lamps and bumpers, and the convertible top, etc.

With the engine in place, the bonnet has now been fitted and adjusted	Rear lights and bumpers now installed
	Windscreen and chrome trim installed

Your car has now been color sanded and buffed and is now back on its wheels. I tried to show in the photographs how straight the doors are, and how well they fit, although the pictures don't really do the car justice.

Back on all 4 wheels	Outside for some photos!
	Opalescent looks good in the  sunlight
	Note how straight the doors are

As you can see, we are now going back together with the front frames and suspension. We have been using your original, black anodized bolts where they can be seen, and new Grade 8 hardware down below. Your door glass arrived today and the Triplex window etching looks good, although one of the pieces of glass has a number of little chips on the upper edge. I don't know whether you are aware of this or not? Perhaps you could give us a call when you get a moment to discuss.

More beautiful Opalescent Dark Blue....

Yesterday your car turned Opalescent Dark Blue! The Glasurit paint is truly stunning in natural sunlight.

Painting in progress
	Outside in the Texas sunshine

Undersealing and painting the underside of the floor.

After masking, we first apply 3M Rocker Guard	The Rocker Guard is then sealed
The sealer is tinted blue		Time for some opalescent dark blue!

The inside of the cabin and the boot compartment have now been painted. Later today we will be refinishing the floor and the underside of the bonnet.

Applying the first of the Glasurit base coat

We are painting inside the car this afternoon. Time permitting, I will upload some pictures of the Opalescent Dark Blue later this evening. Failing that, look for pictures first thing in the morning!

LT fabricated two new horn brackets	The new brackets are spot welded into place behind the headlamps	Seam sealing the cabin
All joints are sealed up prior to painting process		Wurth sprayable seam sealer
		Watch this space!
Sealing the inside	Sealer is tinted blue

The following photographs show Sam trial fitting your chrome trim.

Your car is now in high build primer and the final sanding process will begin next week.

The filler stage has now been completed and your car is in Slick Sand and has the next round of blocking well underway. On Thursday or Friday of this week we will be applying two coats of high build primer, followed by yet more blocking.

We are currently scheduled to complete the final paintwork in about 2 weeks time.
 

First the body was acid washed....	Before being sealed with 2 coats of  BASF etching primer
The darker color is guide coat	Panel fit is truly exceptional
	Seals and latches are installed during this round of blocking

I am pleased to report that all of the sheet metal work and lead loading is now 100% complete. The following photos show Lawrence lead loading around the boot opening and the fitting of the bootlid itself. The old factory lead was melted out and replaced as we had to re-work the rear apron anyway.

Next we will scuff the entire car and seal it with BASF etching primer before embarking on the filler and prep stage.
 

Melting old factory lead
Boot opening re-shaped in lead	Latch and seal is installed at this stage
	Rear apron was re-worked because of old accident damage

Lawrence has been busy reassembling the bonnet and fitting it to your restored tub. He is currently finishing off the lead loading around the bootlid opening and at the top of the rear wings where they meet the upper cowl.

New CJ side frames installed	LT straightening out the bonnet center section
Bellypan bulkhead was painted before  we started assembly of bonnet	Bonnet being assemble in situ
Lead loading cowl fit	Filing off excess lead
Bonnet and door fit in sheet metal and lead		Lead loading the rear cowl

Picture frame is badly pitted
Pin holes revealed by tapping ultra-thin  sheet metal with a pick hammer	The solution....	Panel had rusted through from the inside
Cleaned, acid washed, primed	Body Wax	Shaping a replacement panel
Perfect fit!	Rear cowl will be replaced
Not as big a deal as it looks		New panel fabricated and trial fitted

Installing the other floor and the outer sills....

Applying Body wax to inner sill area		Trial fitting new driver's floor
Outer sill spot welded into place		Drivers floor welded into place
	Installing the LH outer sill

I am pleased to report that we have now begun the sheet metal repairs to your car. The following photographs show Lawrence installing inner sill repair panels, followed by a new cross-member and a new passenger side floor. I hope you enjoy watching as Lawrence does his thing over the next few weeks!

First task is to repair the inner sills	A panel is fabricated and spot welded into place	Trial fitting and trimming the  new passenger side floor
Wurth Body Wax will protect the  inside of the new cross-member	Inner sills were too good to replace, but  needed new lower edge	Starting to spot weld the new passenger floor into place
Everything fits and lines up beautifully		Inner sill will be coated with Body Wax before outer sill is installed

The following photographs show your car after we cut away the outer sills, which were paper thin in places. We also removed the side cowl panels and the main floors, all of which will be replaced. After blasting the inner sill box sections, we carefully sealed the entire monocoque using BASF etching primer.

I am pleased to report that we now have your E Type back from being plastic media blasted. Next week, after spending a few hours with the industrial vacuum cleaner removing all the plastic beads from the various box sections, we will be scrubbing all the welds, seams and joints with acid in readiness for the bodywork ahead.

This project will be getting underway in earnest very soon!