1964 E Type roadster (SB)
Team CJ total restoration
Restoration Log by Dan Mooney


Specification (briefly) for this project is as follows:

Total restoration with a full complement of Team CJ performance and reliability upgrades.


We now have your restored body back on its wheels...




We have now installed the engine frames and the IRS. On Monday morning we will install the front suspension and your car will be back on its wheels.
Installing the engine frames
New black anodized grade 8 fasteners
IRS is already installed


Yesterday afternoon we painted the main outer bodyshell...













Underside of boot lid drying in the Texas sun


More Opalescent Dark Blue....



Time to start applying the first of the Opalescent Dark Blue....





Darrell has spent a solid week grinding, hammering and filing your chrome until it fits perfectly. The only item left to be trial fitted is the new right hand rear bumper, which arrived on Friday. The original rhr bumper blade had obviously been hit at some time in the past and was beyond economical repair.

We are now ready to sand the primer and begin the painting process.

 Metal finishing the front left bumper blade with a hand file
 Trial fitting chrome is a vitally important part of
the restoration process









 Amco bar holes not required
Holes welded up and overrider metal finished 



 Damage to headlamp trim
Repaired and metal finished prior to trial fit



 Trim trial fitted with glass covers in place




Following extensive blocking of the Slick Sand, your car has now been put into high build Glasurit primer. It is now ready for final sanding and painting.









I am pleased to report that all of your bodywork has now been completed and the car put into Slick Sand. The doors, bonnet and boot lid have all been installed with a full set of new rubber seals and slave latches. The panel fit is absolutely perfect. The car looks better than it did when it rolled off the production line in 1964.

Next stage will be to block the Slick Sand with 120/180 grit, before priming and painting.



The following photos show Darrell fabricating a new door top trim panel from scratch, as well as installing perhaps the worst fitting new boot lid we have ever seen!

The original door top chrome finishers are made of plated brass and the chrome plating process can make them very wavy. Next time you are looking at a 6 cylinder E Type roadster, take a peak along the length of this panel and you will understand what I am talking about. This problem is solved by fabricating new finisher panels from heavy gauge steel which can then be metal finished prior to plating. The result is a beautifully straight panel with a spectacular mirror chrome finish.

 Darrell fabricating a new door top
finisher panel



 Notice how the reflection is not
distorted, even before plating
 Panel is tailor made for each door for
a perfect fit
 New boot lid is a terrible fit



 Getting this boot lid to fit properly
will be a challenge
 Right hand side is no better...
First the back edge was trimmed
to create a gap



 Welding up rear edge after trimming



 Starting to look better already
All four corners were built up
with beads of wled



 Left side now has an appropriate gap
As does the right side 


More progress in the Coachworks....

Applying Wurth Body Wax to inner
sill box section
Trial fitting outer sill in conjunction 
with latched door

Sill then spot welded into place
Jacking point is TIG welded

Installing rh sill end closing panel

Time to metal finish damaged rh 
rear quarter

Lots of progress in the Coachworks....

 New inner sills installed
Trial fitting transmission mount 



 Trial fitting LH & RH floors
Spot welding floors together 



 Wurth Body Wax is applied to cross-member 
and inner rear bulkhead
 Torsion bar reaction plate is
installed at this stage
Trial fitting lower engine frame
mounting brackets



 Lower frame brackets welded into
Time to install outer sills 
New floors and inner sills now installed



 Wurth Body Wax applied to
inner sill box sections
 Welding outer sills into place




Sheet metal repairs underway...





The body and associated panels have now been media blasted back to bare metal, and the news really isn't too bad! Although the body shell obviously requires extensive panel replacement, it is far better than most E Types that pass through the Team CJ Coachworks.

We had hoped to save the engine frames, although the blasting process revealed quite a bit of previously invisible corrosion damage. In any event, we will have the resurrection underway shortly!

 Previous repair man applied bondo
right up against the bumper!
 Inner sills way better than most, but
still need to be replaced
 RH wheel arch has some minor corrosion
Time for a closer look after
media blasting
 RH rear 1/4 panel has suffered
some pain in the past
 Bonnet center section will require
extensive work
Doors are exceptionally clean 
Picture frame will be replaced 
 Belly pan will be replaced
 Floors will be replaced
 Boot floor is amazingly sound
 Note rust holes in engine frames

I am pleased to report that we now have this project back underway. In the next few days we be sending the body out for media blasting. Watch this space!


Installing pistons and rods to block...




Installing custom forged pistons to Crower rods...



The following video shows Chris balancing your crankshaft in the CJ machine shop.


Balancing your crankshaft
Forged Crower rods
Finished crank a thing of beauty
Installing upgraded freeze plugs


We have now completed your Stage One cylinder head rebuild and finished all of our machine work on the block. We hope to be reassembling this engine in the next few days.

As it once was....
As it is today...
Honing cylinder to finish size
Block is then painted inside and out
Look closely and you can see the 
cross-hatch honing pattern
Venolia pistons


When we cut away the old exhaust seats, one of them showed evidence of corrosion. This usually means there is a crack (or porosity) in the seat pocket, which can allow coolant to leak through beneath the seat and into the combustion chamber. Fortunately, that proved not to be the case with your head. The first photo below shows the 'rusty' seat after it had been cut out.

I have also included some photos of Chris porting your cylinder head. The last two photos show what a (CJ) ported runner looks like. Once the valve job has been lapped in, the transition between the runner and the base of the seat will be smoothed out so that it is barely visible. I am looking forward to seeing what this head flows when we put it on the bench next week!

Rusty exhaust seat
Unusual staining of pocket
Pressure tested a second time - OK
Chris porting the exhaust runners
Casting quite rough from
the factory
Starting to look a little better..
Finished article a thing of beauty
Intakes should flow big numbers

Stage One engine rebuild underway...

Pressure testing in progress (OK)
Cutting out the old valve seats


Time to get this project underway!

Engine and transmission removed
Floors look remarkably solid
Missing core plug calls for
closer examination
Note factory crayon marks
on firewall


I am pleased to report that your car arrived safely at CJ earlier this morning. We will have your restoration underway very shortly!



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