THE RESTORATION PROCESS

Engine

After disassembly, the block was first taken to American Metal Cleaning (Toledo, OH), where it was soaked in an electrolytic solution for ten days to remove rust inside the water jackets to improve engine cooling. Upon its return, the original cylinder liners where replaced, bored and honed to match the new 9:1 ratio aluminum pistons. The block was decked by LSM Engineering (Waterford, MI) to ensure a true mating surface for the cylinder head. Most machine work was done by Holbrook Racing (Livonia, MI) and Auto Parts Machine Shop (Ann Arbor, MI). The crankshaft was ground and polished by Crankshaft Craftsmen (CommerceTwp, MI) and installed in the block with new bearings and thrust washers. A billet aluminum rear crankshaft oil seal housing was installed with a Teflon seal. This was followed by installation of the new domed pistons, rings and new timing chains. The harmonic damper was rebuilt by Dale Manufacturing (Salem, OR). The original oil pump was upgraded to the 4.2L high capacity pump. The cylinder head was milled a minimal amount to insure a true surface. New valves, guides, seals and springs were installed. Exhaust manifolds received a new black porcelain coating and the downpipes were ceramic coated. After completion, the engine was mounted on a test stand and run for one hour before installation in the car.

Transmission

The Moss four-speed transmission was restored by Vintage Jaguar in Blackfoot, Idaho. In addition, a new clutch disk, pressure plate, slave cylinder and release bearing were installed. The clutch master cylinder was rebuilt by Apple Hydraulics in Calverton, NY.

Differential

The limited slip differential was restored by Coventry West in Lithonia, Georgia. It is a 3.56:1 ratio.

Brake System

The brake calipers were restored by White Post Restorations in White Post, Virginia. The cylinders were bored and sleeved, new pistons were installed and the caliper bodies were zinc plated to prevent corrosion. The front and rear master cylinders where bored and sleeved with by Apple Hydraulics in Calverton, NY. New front and rear brake rotors were installed along with premium brake pads.

Rear Suspension

The rear suspension was disassembled and the cage, axle shafts and radius arms were stripped and coated with black urethane paint. New universal joints were installed on the axles and drive shaft and new bearings and seals were installed in the hubs and hub carriers. New hubs, shock absorbers and springs were installed.

Front Suspension

The upper wishbones, stub axle carriers, front and rear lower wishbone levers, upper and lower fulcrum shafts and mounts were stripped and shot peened, then cadmium plated by Plymouth Plating in Plymouth, MI. New upper and lower ball joints were installed as well as new tie rod ends. NOS Girling shock absorbers were installed.

 Interior

New upholstery was installed by Ogden Top and Trim in Berwyn, IL. Connelly hides cover the seats, while hardura and carpets cover the floor area. The floor and transmission tunnel are covered with Cool-It heat and sound insulation. New vinyl and chrome trim were installed on the new door cards.

Instrumentation was restored by Nisonger Instruments in Momaronek, NY and British Speedo in Goldens Bridge, NY. A period correct Blaupunkt AM-FM push-button radio, restored by Chromelondon in the UK, was installed along with new speakers.

Brightwork

Bumpers, window frames and door finishers were stripped and chrome plated by Saginaw Chrome and Polishing (Saginaw, MI). This shop also polished the engine camshaft covers, front cover, intake manifold and carburetor dashpots. New interior door handles, window cranks, door strikes and exterior door handles and locks were installed. New chrome finishers at the top and bottom of the new Pilkington Triplex windscreen were installed. New Triplex door glass was also installed.

Bodywork

While mounted on the rotisserie, the body was stripped to bare metal. Panels which had more than minor surface rust were replaced. This included the inner and outer sills, the entire floor, bulkheads behind the seats, lower rear quarter panels and the trunk floor, all of which required over 600 welds. To strengthen the body, 1.5” x 2” steel tubing was added along the inside of both inner sills and connected by 2” x 2” tubing running from side to side hidden inside the cross-member. The owner credits Monocoque Metalworks with the idea.

Paintwork

Bare metal was first coated with a layer of epoxy primer and three coats of urethane primer. It was then carefully block sanded to a perfectly flat and smooth surface. Subsequently, two coats of Lesonal red basecoats were applied, followed by three coats of Lesonal Univeral Clearcoat. After a month of drying time, the clearcoat was sanded with abrasives ranging from 1000 to 3000 grit, then polished with three grades of 3M polish to a mirror finish. The undercarriage is finished with matching paint (see video link on main page).

Hood (top)

The car was taken by trailer to Wyoming, Rhode Island where a new convertible top was sewn and installed by Bassett’s Jaguar. This top was crafted using the very best material (Haartz Stay-fast cloth) and sewn with the seems in the exact location of the original top and has the sewn-in weighted wind anti-buffeting bag, per original. New chrome clamps were installed in the center and each corner of the canopy.

Wheels and Tires

This car features new Michelin 185 VR 15 XVS tires mounted on new 72-spoke Dayton 6 x 15 chrome wire wheels. An identical spare is in the boot, along with an original jack and complete original tool kit.

Fuel System

A new fuel tank has been installed, complete with new fuel pump and fuel level sender. The three SU HD8 carburetors have been rebuilt and synchronized.

Body