1955 Jaguar XK140 DHC (JK) Major mechanical overhaul and interior restoration

Specification (briefly) for this project is as follows: Interior trim replacement, wood restoration and major mechanical rebuild and upgrade..

I am pleased to report that your engine rebuild has now been completed and we will be reinstalling it in your car in the next few days.

Balancing CJ alloy flywheel	Custom Cometic gasket used to manipulate desired compression ratio
	Almost ready to reinstall

Your block machine work has now been completed and we are in the process of assembling your engine.

Balancing the crankshaft
Block is painted inside and out
CJ forged pistons hung on rods

Maybe the prettiest valve covers in the automotive world....

Kevin completed your align hone to virtual perfection - less than .0001" (one tenth of one thousandths of an inch) across all seven main caps.

More progress in the machine shop, including a beautiful set of forged XK pistons...

Surfacing block after sleeving	Oil pan needs some TLC
Shaping the repair panel
Repair panel welded in place	New product - CJ forged pistons for the XK range

I am pleased to report that we have now rebuilt your cylinder head. Kevin has your block in process, so it should only be a few days before we have the engine build completed.

Preparing to install new tappet guides	Machining intake side of head after welding up corroded areas
Surfacing cyl head surface	The finished article, better than new

Lots of progress with the engine build this week, although we have run into a number of problems with the cylinder head. Unfortunately, all the tappet guides are well out of spec and will have to be replaced, and the pockets for the valve guides are extremely large and will require oversized custom replacement guides. All six spark plug holes will also need helicoil thread repair.

This cylinder head has obviously been ported in the past, presumably in 1986 by a company called "Jag Tech", who left their mark on the underside (see last photo in sequence below).

	Cylinder head has a number of issues
All 12 tappet guides will be replaced	Corroded areas will be welded and machined
All 6 spark plug holes will receive new threads	Boring the block for new sleeves
Head has been ported in the past	Amazing to think 1986 is now 25 years ago...

Time to get this engine rebuild underway...

Kevin using machine shop crane to remove the cylinder head	Oil pan will need some attention

Time to remove and rebuild the engine...

The finished (heater box) article...

Your heater box doors were missing in action, so Darrell fabricated a new set for you. I thought you might find it interesting to see how he made them.

The circular item on the left is called a Hammer Form	Stock sheet metal is bolted to the Hammer Form...
The edges are hammered to form requisite flange	Making a card template of the shape of the missing doors
	Job done, ready for paint

Retrimming the front seats...

More progress inside the car...

Minor gauges are a little rough and will be rebuilt
	Rear compartment virtually complete
Trimming seat backs...

Lots of progress in the trim room...

One of your top latches is cracked and will be replaced	Flocking has largely worn off inside glove box
	Glove box media blasted
	Reflocked
Almost time to restore the seats	Dash is shaping up nicely
Seat frames have been media blasted and painted

Assembling the door casings, trimming rear bulkhead...

Driver's door fully assembled	Interior starting to take shape

Interior trim restoration, continued....

Passenger inner B pillar corroded at bottom	We fabricated a replacement panel
New panel trimmed out and installed	Driver's door panel installed

Time to start installing the new interior...

Much of the interior brightwork has been replated	Time to start installing the new interior...

We now have the new Suffolk & Turley interior kit in hand and will begin the interior restoration for you in the next few days.

We have now received your re-veneered interior wood back from Madera Concepts and I am pleased to report that they did a spectacular job. My photographs do not do it justice as it is absolutely stunning.

We have now removed all the interior wood from your car and sent it off to the good folk at Madera Concepts in California, where it will be re-veneered and polished to perfection.

	Home made door panel trim really had to go
Inner door frame not pretty, but it is solid enough...	Wood trim removed and ready to ship
Main gauge panel had damaged veneer	Wood wasn't terrible, but did have a number of blemishes
Every piece will be re-veneered at Madera Concepts

I am pleased to report that we now have your car in the trim room and have begun the interior restoration.