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Aston Martin DB4 Series 5 Vantage Restoration

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1963 ASTON MARTIN DB4 SERIES 5 VANTAGE RESTORATION

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1. INSPECT AND REPORT

This initial stage enables us to carry out a complete report of the vehicle. It entails a detailed inspection of the chassis, aluminium panels, originality and any missing parts. If roadworthy, we carry out an extended road test to ascertain engine, gearbox and axle condition.

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2. DISASSEMBLY

Once our initial assessment is complete, we dismantle every mechanical and body component, categorising them for refurbishment or replacement. The major components (engine, gearbox and rear axle) are also dismantled, enabling us to fully evaluate their condition. At this point, a final estimate can be provided along with a timescale plan.

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3. REMOVE PANELWORK AND SHOTBLAST CHASSIS

The aluminium front and rear body panels are now carefully separated from the steel chassis. The chassis is then shot blasted to remove the old under-body sealer and expose any corrosion.

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4. REPAIR CHASSIS AND STOVE ENAMEL

Once the corrosion is removed, new replacement sections are fabricated on site and welded in place. This is done in such a way as to keep all repairs looking completely authentic, whilst matching original welding techniques. Finally the repaired chassis is stove enamelled to ensure the best possible rust protection for years to come.

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5. REFURBISH AND REFIT PANEL WORK

The front and rear body sections, along with the bonnet, boot lid and doors, are chemically dipped to remove the old paintwork. This process is far more advantageous than the traditional method of paint stripping and sanding, which thins the aluminium. Each panel is carefully assessed, and then either repaired or replaced depending on condition. The aluminium front and rear panels are refitted, with the door fits, bonnet and boot gaps being set, followed by a full body fitting pre-fit.

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6. PREPARE AND PAINT BODY

The bodyshell is meticulously prepared for the paintwork using the latest products to ensure a finish of the highest standard. We have the technology available to match any colour, or to re-produce any original factory colour.

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7. REBUILD ENGINE

Having been chemically cleaned and pressure washed, the engine is completely stripped, and all components are thoroughly inspected. The cylinder block and head are vapour blasted, whilst other items are re-plated, re-chromed or stove enamelled to achieve the required finish. The engine is then built to the customer’s unique specification.

Having an in-house dynamometer allows us to fully run-in, set-up and power test each engine to maximise performance, reliability and efficiency.

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8. FITTING-OUT STAGE AND MECHANICAL BUILD

All of the refurbished and new body fittings are installed, and the re-chromed bumpers and door frames are positioned and adjusted. Complete electrical systems are fitted with new or refurbished wiring harnesses and components.

A brief visit to our trim shop at this point takes place to install a new headlining of the customer’s choice, followed by the fitment of the front and rear screens. The mechanical build is then carried out, with the synchronised refurbishment internally of the key components, which is vital to ensure a cohesive rebuild framework.

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The key stages are:

1) Powder-coated front suspension, rebuilt with new components and overhauled rear axle installation.

2) Braking system installed, including master cylinders, servos, pipework, pedal gear, discs and calipers.

3) Fuel system, pipework and tank fitted.

4) Full engine bay refit, allowing the rebuilt engine and overhauled gearbox to be installed.

5) Cooling and exhaust systems installed.

This stage culminates in a fully functional car, allowing the final visit to our trim shop. New Wilton carpets are handmade for the car, with all the leather replaced by craftsmen with over 30 years’ experience of Aston Martin trim work.

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9. The Completed Restoration

Now we have a fully rebuilt, repainted and re-trimmed car. The final test drive and inspection ensures that every aspect of the work has been completed to our own exacting standards. Not only is it vitally important to us at Aston Engineering that every one of our restorations is cosmetically perfect, but it is also crucial that they drive and perform just as well. Our meticulous attention to detail, coupled with our experience and expertise, ensures we hit the target every time.

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"WHY NOT VIEW SOME OF OUR OTHER PAST RESTORATION PROJECTS BELOW"

David Jack - Director

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