E-Types rely on their monocoque (or unibody) structure in place of a typical car’s frame. Therefore, a solid, straight, properly repaired body shell is an important foundation for your restoration – and a MUST for your safety! Let our experience with this specialized repair ensure perfection!
Monocoque Metalworks is a unique E-Type shell restoration facility! The marriage of our shell restoration service and our E-Type Panel fabrication shop is a winning combination! By making all of our own panels, we can ensure that every single piece of your shell is IDENTICAL to the original specs. This also means that we also don’t have to wait for back-ordered panels to arrive for your restoration to continue. Once begun, your shell progresses rapidly and is back in your hands quickly!
Inspection, disassembly, paint and rust removal. Your E-Type body shell will be inspected for rust and accident damage, and a ‘plan of attack’ will be agreed upon concerning which panels will be restored and which will be replaced. The monocoque will be carefully disassembled and stripped with a combination of methods. Plastic media, soda, sand (only where absolutely necessary for rust) and even hand-applied chemicals will be used to reveal clean metal without warpage.
Rotisserie restoration. The bare shell will then be mounted into our ‘rock-solid’ rotisserie to ensure perfect alignment throughout the restoration. Unlike many other shops, we use a rotisserie that does not rely on the tub itself as a part of the rotating structure, and allows quick and easy 360-degree rotation. This level of access to the shell means that we don’t have to make ANY compromises in welding techniques or quality during repair.
Shell preparation. Next, all panels to be replaced will be carefully removed with professional tools that minimize or eliminate damage to the panels that will remain. The tub will then be coated in PPG DP-series 2-part epoxy primer, and the remaining bad metal removed and the flanges of remaining panels restored.
Panel Replacement. New panels will then be welded in using a combination of methods including Spot, Plug, MIG, and TIG welding, depending on what the specific panel or repair calls for. On some panels, we even braze the seams – exactly like the factory. We duplicate the original assembly methods as closely as possible, while also adding strength and safety to the structure. All overlapping flanges will be coated with ‘weld-through’ zinc-oxide primer before assembly. Our welding equipment is top-quality, industrial-grade machinery, and our welding skills have over 20 years of experience behind them – you can expect, and your shell will receive, absolute perfection in every single weld.
Perfect alignment is constantly ensured. Throughout assembly, the alignment and dimensions of the tub will be checked and re-checked, and also compared to factory Jaguar blueprints and crash measurements. In addition, the fit of doors, decklids and hatches, top frames, front subframes, and the bonnet will be continually checked throughout the process.
Because our shop is specialized, we can complete this work at a VERY reasonable cost. The fabrication of our own perfect panels means MUCH lower materials cost for your project. Time and cost are also saved by eliminating the need to “fit” other manufacturers less accurate panels – our panels ALWAYS fit. All of our machines and jigs are setup for E-Type shells, and your project moves through the restoration process quickly and efficiently, saving time and expense.
In conclusion, we are the answer you have been looking for! We can restore ANY condition E-Type monocoque to indistinguishable from the day it left the factory. There is no such thing as a ‘parts car’ at Monocoque Metalworks – you can bring us your shell in TWO PIECES if it is that far gone – NO PROBLEM! We can also make improvements and modifications if you desire, such as extra internal gusseting, improved radius arm mounting points for high horsepower applications, roll bars, etc. We can even convert a coupe tub to a roadster if you wish! Give us a call and let’s discuss your project today!
Monocoque Metalworks – (443) 907-2287 – Chuck
References available – or come visit and see our tools and skills in action!