1967 E Type roadster (BD) Mechanical rebuild

Specification (briefly) for this project is as follows: This car has been 'under restoration' in another shop for approximately 10 years. Our brief is to put everything back together mechanically - and finally get her back on the road!

We have now align honed and resleeved your block, re-surfaced the deck and honed the cylinders to size ready for the new Venolia forged pistons.

Measuring main caps	Align bore in progress
Old sleeves cut away	Cylinder cut to receive new top hat sleeves	Timing chain cover is junk and will be replaced
Setting up to re-surface block after re-sleeving		Replacement timing chain cover is machined with block
Honing new sleeves to size

The following sequence of photographs demonstrate a number of problems with your cylinder head. As it is the original matching number head, we are going to do our best to save it, although it is very badly warped and has already had a lot of material removed from the deck surface. Hopefully we will be able to straighten it and still have enough material to work with to re-surface it.

Head is warped	Measuring more than .050"	Note uneven bearing wear and remember this is an engine that has never been run
Measuring warpage along the cam saddles	Measuring the run-out on the previous valve job	.004" run-out is way out of spec

I am pleased to report that your car is safely inside the CJ workshop where we already have the rebuilding process underway. Unfortunately, as you suspected would be the case, the engine rebuild you had done elsewhere has a number of serious issues. The valve seats in the cylinder head have been machined incorrectly, at too great a depth, corrosion issues in the chambers were not addressed, and the re-surfacing job done on the cylinder head deck is about as bad as it could be.

The block also appears to have had sleeves installed within sleeves, which is a totally unacceptable practice. The bottom line is that we already have a much needed full (Stage One) CJ engine rebuild underway.

I hope you enjoy watching the rebuild of your E Type on these pages over the next few months.

	With the head removed, we were able to inspect the quality of the previous rebuild	Difficult to photograph, but the previous valve job was not of good quality
	Re-surfacing job scored the deck surface very badly