Complete Teardown: The team performed a full "nut and bolt" strip-down, removing the windows, engine, interior, and trim until only a bare shell remained [09:39].
The "Lift of Doom": Initial inspections on the lift revealed poor jacking point repairs and various amateur "patch" welds on the chassis [06:58].
Chassis & Bodywork Restoration
Media Blasting & Stripping: Once the paint and underseal were removed, significant hidden rust and "bodge" repairs were discovered, including mesh and filler used to hide holes [13:53].
Structural Welding: The shell was placed on a rollover jig (rotisserie) to allow for precise welding [10:23]. Major work included:
Replacing both sills and floor sections [18:52].
Installing new wheel arches and repairing inner sills [18:59].
Fabricating new chassis legs and spring hangers [11:53].
Panel Fitting: The team used a mix of handmade metal fabrication and ready-made repair panels, which required extensive modification to achieve a perfect fit [15:21].
Engine & Mechanical Overhaul
Engine Blueprinting: The 1600cc Kent crossflow engine was stripped and found to have been previously "overbored" by .030, effectively increasing displacement to nearly 1700cc [18:27].
Performance Upgrades: The cylinder head ports were polished to reduce friction, and new inlet valves were installed [09:00], [20:43].
Reassembly: The engine was rebuilt with a new head gasket and a four-branch exhaust manifold, while the iconic Twin Weber 40 carburetors were retained and refurbished [21:18], [25:44].
Bench Testing: The engine was successfully "hot-tested" on a trolley before being reinstalled in the car [21:30].
Paint, Suspension & Final Assembly
Paintwork: The shell was finished in its original Sebring Red, with the team noting that the finish was "outstanding" compared to factory standards [23:02].
Undercarriage: All running gear was sandblasted and repainted. The car features McPherson strut front suspension and classic leaf springs at the rear [23:28], [24:10].
Final Details: The car was fitted with its correct steel wheels and detailed trim to return it to its authentic factory specification [25:11].