It Started With a Cup of Tea
One of the things we really enjoy at OCR Rally is being able to show people around our workshop.
It's not unusual for passers-by to find themselves distracted by the beautiful – and sometimes unusual – classics regularly arriving at or leaving our premises. So, when a prospective client calls to ask about our experience or standard of work, sometimes the easiest answer is simply: come over, have a cup of tea and see for yourself.
That was exactly how the story of this Jaguar XK120 began.
The initial meeting was straightforward. The owner had a cherished XK120 that he knew needed some attention and was looking for someone he could trust to carry out the work properly.
After the introductions, we headed into the workshop. The cleanliness of the facility and the variety of projects underway immediately made an impression. One car in particular sparked plenty of conversation – a Jaguar XK150 we were in the process of comprehensively restoring.
At that stage, the XK150's body had been reunited with its chassis and installation of the new wiring loom was about to begin.
The conversation continued and, before long, a second meeting was arranged.
The XK120 Arrives
This time, a beautiful dark blue Jaguar XK120 took centre stage.
With its sweeping wings, long bonnet and unmistakable profile, the XK120 is one of those cars that commands attention before the engine has even started.
The brief from its owner was relatively simple: he needed someone he could trust to look after his pride and joy.
There were several known issues. The clutch required replacement, the brakes were pulling and areas of the bodywork were beginning to show their age, with corrosion starting to bubble through the paint. Left untreated, these areas would inevitably deteriorate further.
The owner had also lost confidence in the car's electrical system. Numerous alterations had been made over the years to wiring that wasn't exactly renowned for its reliability when new. Having seen the new loom being installed in our XK150 project, the decision was made to take the same approach with his XK120 and start again properly.
Finally, there was the engine bay.
Classic Jaguar engine bays can be a thing of beauty, and this XK120 wasn't going to be an exception. The engine bay would be repainted, with its components removed, inspected, cleaned and refinished before reassembly.
With the scope agreed, work could begin.
Starting With a Proper Inspection
Before reaching for the tools, we started with a road test.
This immediately highlighted a firm but unusually low brake pedal. The power steering – a later addition to the car – also appeared to operate whenever it felt like it, cutting in and out intermittently.
The XK120 was then moved onto a ramp for a more detailed inspection.
Further issues were identified, including tired wheel bearings and track rod ends. Everything was documented and discussed with the owner before any additional work commenced.
This gave both us and the client a clear picture of the car's condition and allowed the project to progress in a controlled and considered way.
Rebuilding the Braking System
Investigation into the low brake pedal led us to the front brake adjusters.
The teeth had worn significantly, allowing the locking mechanism to slide backwards rather than maintaining the correct adjustment. Combined with leaking wheel cylinders and tired brake shoes, it was clear the braking system required more than a simple adjustment.
The rear brakes told a similar story.
We methodically worked through the system, replacing worn or leaking components where required and rebuilding the brakes to make the XK120 safe, predictable and enjoyable to drive once again.
Tackling the Corrosion
With the mechanical work underway, the exterior was stripped in preparation for the bodywork.
Visible areas of corrosion were carefully taken back to sound material and the metalwork repaired as necessary.
The windscreen also had to be removed to allow us to properly investigate corrosion around the aperture. Once exposed, both corners of the windscreen surround showed considerably more deterioration than was visible from the outside and required extensive repair.
It is exactly why addressing bubbling paint early is so important on a classic car – what appears minor on the surface can often be hiding much more underneath.
With the necessary repairs completed, the body could be properly prepared for refinishing.
Restoring the Engine Bay
At the same time, we continued stripping the engine bay.
The engine itself was removed, giving us unrestricted access and the opportunity to inspect areas that would otherwise remain hidden.
During this process, we discovered that one of the engine's core plugs had been weeping. After discussing the finding with the owner, the decision was made to replace the complete set for peace of mind.
The owner had also become increasingly concerned about the amount of engine oil being left on his driveway, so with the engine already removed, it made sense to replace a number of accessible external gaskets and seals.
While everything was apart, the remaining engine bay components were cleaned, inspected and refinished ready to return to their freshly painted surroundings.
The carburettors were also rebuilt after the owner reported occasionally noticing the smell of fuel around the car after it had been standing.
A New Lease of Life
The XK120 was delivered to our bodyshop and we eagerly awaited its return.
Although the majority of the body was fundamentally in reasonable condition, the work transformed the entire appearance of the car.
When it returned to OCR Rally, the finish immediately impressed the team. The deep blue paint beautifully highlighted the flowing lines of the XK120 and there was a genuine sense of excitement about putting the car back together.
But before the polished brightwork could return, there was another major job to complete.
Starting Again With the Electrics
The first major component installed into the freshly painted body was the completely new wiring loom.
Historical photographs and reference material were used to ensure the loom was routed and secured correctly, retaining an authentic appearance while giving the owner confidence in the electrical system.
As part of the installation, LED stop, tail and indicator lighting was incorporated to improve visibility and reliability.
We also completely rewired the previously installed power steering system, eliminating the intermittent operation experienced during our initial road test.
The aim wasn't to unnecessarily modernise the XK120. It was to make sympathetic improvements where they would make the car safer, more reliable and ultimately more enjoyable to use.
Bringing It All Back Together
Before reinstalling the engine, the clutch was replaced and time was taken to clean and repaint the visible areas of the chassis.
There is something particularly satisfying about assembling a classic car once every component has been cleaned, restored and refinished.
The rebuilt and detailed engine was carefully returned to its freshly painted engine bay and, piece by piece, the Jaguar began to come back together.
The exterior followed.
All of the car's brightwork was carefully polished to give it the finish it deserved. Trim, lights and exterior fittings were methodically reinstalled, with the iconic front grille one of the final pieces to return to the car.
The grille itself had previously undergone repair to straighten several of its characteristically delicate vertical slats, ensuring the centrepiece of the XK120's front end looked every bit as good as the surrounding bodywork.
Back Where It Belongs
With the Jaguar finally back in one piece, the last stage was extensive road testing.
Several miles were completed to make sure the XK120 drove every bit as well as it now looked.
Minor adjustments were made to the vehicle's geometry and engine tune before we were satisfied that the job was complete.
The result was a beautifully presented Jaguar XK120 with its underlying mechanical and electrical issues addressed, corrosion properly repaired and an engine bay worthy of one of Britain's most iconic sports cars.
Most importantly, its owner once again had confidence in his cherished Jaguar.
From a conversation over a cup of tea to handing the keys back to an owner who couldn't wait to get behind the wheel – this project was about preserving everything that makes the XK120 special while making sure it could continue to be driven and enjoyed for years to come.
