1960 Jensen 541S

Peony Red Paint Prep

Our 1960 541S Jensen has been continuing its paint process with the bonnet and wings being masked, prepped and primed and the undersides painted black.

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2020 In Reflection

It goes without saying, 2020 has been tough for everyone but there have been some positives! Bridge Classic Cars turned 16, we welcomed in more

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Jensen Assembly

Our Peony Red 1960 Jensen 541S is getting closer and closer to evolving into a beautiful Peony Red classic. Before it can be painted, our

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Workshop Walkabout

Our week has been very busy with two photoshoots at the start of the week and new projects arriving in the workshop. Tr6’s new hood

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Workshop Walkabout

There’s been a lot going with week already and its only Wednesday! Take a look at what’s been going on s far. Range Rover Sport

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The Mystery Stopper

Some drama in the engine workshop! All was seemingly well with the engine re-build however, unbeknown to us, the dipstick tube had previously broken off

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Sitting Tight

More work has been done on our 1960 Peony red Jensen 541S. The latest instalments are the seat covers and pockets that have been made

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Friday Snapshot

Its been a busy week, with once again, many cars leaving, lots making big milestones and photoshoots! Behind the scenes on the Rolls Royce shoot

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The Girl In Red

You’d be right in saying that this isn’t a red 1960 Jensen 541S. But with a bit of imagination and a lot of hard work

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Visit to Paint & Trim

We popped into our in-house paint and trim shops this afternoon to check out what our classic car technicians are working on today. Darren, one

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Vapour Blasting

These car parts have all undergone a special cleaning treatment of vapour blasting here at our Pettistree workshop. The inlet manifold, cam cover, sump and

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Jensen Journaal – July 2021

It is lovely to receive a copy of the Zomer 2021 Jensen Journaal in the post this week.

Several of our Jensens that we have restored have been featured in this month’s copy of the Dutch magazine, Jensen Journaal! https://jensenholland.nl/ It’s an absolute privilege, so thank you.

The magazine talks about our 1957 Jensen 541R, the 1958 Jensen 541R, the 1960 Jensen 541R and the 1960 Jensen 541S (The Prototype).

Here are our website links to the cars that were featured to find out more information on each of the restoration projects.

https://www.bridgeclassiccars.co.uk/category/projects/completed/1958-jensen-541r-navy/

https://www.bridgeclassiccars.co.uk/category/projects/completed/1957-jensen-541r/

https://www.bridgeclassiccars.co.uk/category/projects/completed/1960-jensen-541r-01/

https://www.bridgeclassiccars.co.uk/category/projects/completed/1960-jensen-541s/

Jensen 541S Air Box Bolt

Paul has re-produced an air box bolt for our 1960 Jensen 541S air box. It is now complete and ready to fit.

Bespoke Jensen book bag!

We call it the Jensen bible and in order to protect it Kath has made a bespoke leather book bag.

Jensen Genome Richard Calver July 2019 Edition

She started the process by drawing, measuring and working out the dimensions and design for the bag. Black leather was cut out to the required shapes and measurements and then mounted onto 3mm foam. She then sewed around the edges of the mounted pieces to make sure they were secure.

The first step in putting it all together was to sew a zip between two pieces of mounted leather with a zipper foot. Red topstitching went down either side of the zip as a finishing touch. Kath attached the zip and sidebands with clips onto the front of the book bag, to make sure it all fitted together, before sewing in place. She checked the book fitted inside, before sewing the back of the bag on. Red topstitching running around the outside edges of the front and back matched the zipper.

Jensen 541S engine running up

Please to show our Jensen 541S bursting into life and sounding beautiful.

Next job will be to set the gearbox up.

Red Jensen interior fit continues!

Thomas has been fitting the mushroom shade leather front seats into the peony red Jensen. He first had to fit runners into the front of the car, these are bolted in, either side, as a pair. The seats then slide onto these with attachments on the bottom of each front seat. These runners are what make the seats move backwards and forwards, to give more or less leg room in the front!

Thomas has also fitted the centre mirror, centre console and sun visors.

Kath has been making a boot carpet for the Jensen 541s too. She made a carpet cover for the fuel pipe, to match the boot. These were both made by her creating a paper pattern first. All the edges of the carpet were binded in the mushroom leather.

Jensen 541 – Spare Wheel Carrier and Dash Modifications

Tamas has manufactured a spare wheel carrier bracket to hold the carrier in place.

Having recently recovered the original dash, when fitting to the car we recognised that the dash was slightly larger than required. We have now stripped the dash back to reveal the area that requires adjustment. It has now been rectified and re-covered to make a perfect fit in the car.

And finally, Tom has fitted the grommets under the engine area.

Peony Jensen Update

The exhaust on our Peony Jensen has been fitted by Demand Engineering. We now need to put the seats and pins in, air filter, bleed the gearbox and modify the number plate.

Peony Red’s Boot Lid Interior

Our 1960 Peony Red Jensen has had a new boot lid carpet. Brian has cut and glued a leather strip around the inside edge of the boot lid and then glued down the carpet to the inside, cutting holes in the boot to support the arm and catch.

We’ve also sent the entire car off to Demand engineering to get the exhaust manufactured and fitted. We’ve found that the profile of the downpipes are not the correct profile so we’re also having them re-profiled so that they allow the exhaust to sit correctly.

Peony Red Paint Perfections

Chris has been neatening up one of the side panels to correct some imperfections that have happened whilst assembling the car. It’s very common for scratches and knocks to occur when building a car back together and luckily Chris is on hand to correct any accidental damage.

Peony Red Is Finding Its Voice

Our 1960 Jensen 541S, fondly nicknamed ‘Peony Red’ after its colour, is currently having its horns fixed by Tom. He’s also checking over a few issues with the wiring and ensuring that the lights work and the earth cable is responding correctly.

Peony Windows Fitted

Our 1960 Peony Red Jensen 541S has had the windows fitted and is now resembling more and more of a working car.

Peony Red Jensen Gets New Carpet

Kath has made a boot carpet for out 1960 Jensen 541S. She begun by inserting rubber grommets in the holes, made templates and then cut out the patterns. When she had cut out the carpet, she could bind and shape the edges.

Peony Red Air Vents

Kath has made a cover for the metal plate Paul made as part of the windscreen air vents.

Peony Red Jensen’s New Chrome and Dynamometer

Our 1960 Jensen 541S has had new chrome fitted around the door as well as ‘weather strips’. Paul has been working to apply the smaller chrome details.

Paul has also fitted a new dynamometer.

Peony Jensen Tweaks And Adjustments

Our 1960 Peony Red Jensen is having its newly built dashboard fitted by Tom and the chrome adjusted by Paul.

Kath has continued with the door side panels and had now completed the passenger side. She has screwed in the panels for the air vents, added carpet fasteners and was then ready for Tom to work on the dash and Paul to work on the chrome.

Peony Red Jensen’s New Dash And Door Cappings

Tom has been working on building up the dashboard for our 1960 Peony Red Jensen 541S. A keen eye for detail and a steady hand is needed to build up dashboards as it is a tricky job.

Brian has been adding wood to the front door to make the capping fit correctly. He’s then covered the door capping and new board for the side panel and added in a seat belt slot. Lastly he added the pipping between the side panel and rear quarter panel and glued it all in place.

Sound Deadening The Peony Jensen

Kath has been laying sound deadening in the Peony Red 1960 Jensen 541S which is starting to look more and more complete.

Kath began by covering the section of floor she was working on, with leather and then started to lay the sound deadening, being careful to check how each piece fitted and glue them securely in place. She then went over the sills and added the carpet under the rear seats and bound the ends. Then Kath started laying the carpet in the passenger footwell, around the side of the centre tunnel and bound the edges.

Peony Red Headliner Continues

Kath has continued on the 1960 Jensen 541S Peony Red headliner by bolting in the screws in the front header rail. She’s then covered the B posts in leather and added 3mm of foam to the rear. Kath has then covered the back parcel shelve in the same headliner leather and then followed it up by fitting the panels along the top of the head liner.

Next up, Kath made a pattern for the rear pocket sections and then glued it in place. She then removed the seat belt to fit the rear quarter panel. She then modified the rear quarter panel to make it fit better. Kath then attached the rear door capping and rear panel as well as fitting the seat belt back in place. She then repeated this process on the driver’s side.

Once everything was covered and fit, Kath could lay the rear seat in place to make sure it all fits. Next up is the sound deadening and carpet.

Peony Red Jensen Gets New Badges And Headliner

The owner of our Peony Red custom 1960 Jensen 541S took the decision to get the badges painted in a diamond red as he didn’t like how the silver looked. Here’s the before and after:

Kath has also fit the headliner for our Peony Red Jensen. She begun by attaching the metal rods to the edge of the car and then attaching the leather around the windscreen. The next step was to attach the front header rail and then screw it in place, lining up the holes.

Peony Red Jensen Bonnet Catches

Paul has manufactured some new bonnet catches for our 1960 Jensen 541S. These components are crucial to keeping the bonnet closed and secure. Being made by hand, these catches have been designed and made to fit our Jensen perfectly.

Peony Red Grills And Shields

Paul has fit the heat shield into the engine as well as the front grill and badge into our 1960 Peony Red Jensen 541S. Every day our Peony Red is starting to resemble a real car more and more as it makes exciting developments daily.

Peony Red Gets More Chrome

Our 1960 Peony Red Jensen is coming along well. With the continuation of chrome fitting, Paul has been making an fitting seat belt strengthens to ensure safety. Originally only being fitted to the metal shell, Paul has made some enforced pieces of metal to make sure the seat belts are fixed in well.

Tom is also linking up the main loom to the fuel gage and reserve, as well a securing it in place so that it runs to the rear loom.

Peony Red Jensen Taking Shape

Our stunning custom build Peony Red Jensen is really taking shape now. Thanks to the continuous hard work from our skilled classic car technicians, this classic is looking more and more like the beautiful motor it was meant to be. Stay tuned for more exciting updates!

Peony Red Jensen’s Wiring Loom Fitted

Tom has begun to catalogue the different wiring looms for our 1960 Jensen 541S. He’s started with the rear wiring loom, connected the rear indicators, brake lights, sidelights, number plate lights and the reverse light. Tom has also allocated the rear wiring loom in the rear junction box. He has then continued to install the bonnet wiring loom and has connected the headlights, indicators and sidelights wirings to the bonnet wiring loom.

Paul has also fitted the rear bumper.

Lydia has also taken apart the head lining. She’s started by laying out the old fabric to see what it looks like. Once she made the new version, she sewed in calico loops onto each headlining part while attaching the sections together.

Peony Red Jensen Fitting And Fixing

Paul and Tom have been working on the Peony Red Jensen 541R today, both fitting more chrome to the body and fixing in place the underside bonnet clips.

Paul has been steadily getting through all the chrome pieces, fitting them to the body and ensuring they all sit perfectly. Tom has been fixing in place the clips which hold in place the bonnet rods and hinges that allow the bonnet to open.

Tom has also assembled the dash, fitted the boot and bonnet as well as fitting the indicators and chrome.

Peony Red Jensen Assembly Continues

Our lovely 1960 Peony Red Jensen 541S is at the stage where we’re putting lots of pieces back together and fitting them in, meaning that day by day, its looking more like a Jensen. Paul has fitted the vacuum pipe for the carburettor manifold as well as working alongside Tom to fit the sills. With the doors now on as well, the body of the car is more or less recognisable.

Peony Red Jensen Progression: Trim, Engine And Steering

Brian has been working on the door cappings for our 1960 Peony Red Jensen 541S. He began by fitting metal brackets to the rear door capping and then glueing in the wadding. Brian then glued the leather cover to the door capping and turned the leather over onto the back to neaten up the corners and pull taught the material.

Paul and Ady have recently fit the engine into the Jensen which is arguably one of the key milestones in a restoration. With this now in place, engine refurbishments and adjustments can be made to ensure its up and running.

The assisted power steering pump has also been prepared and fitted into our Jensen.

Peony Red Project Continues

The bonnet, boot and internal components have been painted for our 1960 Jensen 541S. The parts sat in primer and a base coat before having their iconic Peony Red paint applied. The internal parts and engine block have been painted black to keep them uniform with the rest of the internal elements.

Paul has been working on the mechanical elements for our Jensen, which has included fitting the rear section boot floor, new hand brake cables, and re-manufactured the bolts on the rear axle half shaft.

Ady has been working on refurbishing the engine by attaching a new rear seal conversion and replacing the bolts that hold it in and fitting a new cylinder head with new valves spring and valve guides. The engine has also been rebored to take new pistons, the crankshaft has been reground and new bearings fitted. A new timing chain, cam followers and gaskets have also been fitted.

Ady and Paul are have also been working on fitting the re-conditioned gear box to the engine.

We’ve also fitted the rear lights this week, ready to be wired in.

Twenty Twenty: The Year Of The Jensen

Some of you may remember we mentioned our busy Jensen workshop last year, and it hasn’t slowed down in 2021. We’ve become the Jensen Specialists of the UK with a constant set of Jensen 541R and 541S projects passing through our doors on a regular basis. With projects ranging from full nut and bolt restorations to small fixes and services, we’ve been inundated with Jensen’s, and we love it!

2020 saw 8 Jensen’s in at the same time, which led to this amazing shot of them all lined up. Our technicians are now well versed in Jensen mechanics, electrics and bodywork as we’ve still got 6 of them in the workshop plus another stored at Bentwaters waiting to find a new home.

With only 193 Jensen 541R’s ever made and 127 541S’s made, and even fewer still on the road, we’ve had a large quantity of them in the workshop.

Peony Jensen Heat Shield

One of our technicians, Pauls, has made and fit a heat shield for our 1960 Peony Red Jensen 541R. Paul has cut out, measured up and fitted the panels which are made up of Asbestolux.

Peony Red Mechanics Underway

The Peony Red Jensen, now finished in paint, has been moved into the workshop to begin its mechanical journey.

Our technician Paul is currently fitting new brake lines as the original ones are worn out.

Peony Red Paint Prep

Our 1960 541S Jensen has been continuing its paint process with the bonnet and wings being masked, prepped and primed and the undersides painted black.

Peony Red Jensen Painted And Ready

We’re delighted to announce that after being smoothed and polished, our beautiful Peony Red Jensen has entered the trim shop.

Chris spent yesterday smoothing and polishing the body so that the paint looks smooth and perfect. We’re loving the richness of the red contrasting with the soft grey roof.

This 1960 541S Jensen is now sat in our trim shop ready to start its interior restoration journey.

The Peony Red Grows

Chris has been working on some of the exterior panels for our Peony Red Jensen. Although the body can be painted in one go, the exterior panels and doors need to be done separately to ensure the paint can get into all the details.

Here Chris is painting the wings with the Peony Red and a clear coat. The wheels have also been primed and painted.

Our Peony Red Jensen Has Blossomed

Yesterday afternoon was the moment we’ve all be waiting for. The first drop of Peony Red paint has been applied to our 1960 541S Jensen. For months we’ve been watching our skilled technicians work on rebuilding and reworking the body of this Jensen and finally its entered the paint shop.

This is a very exciting development in this restoration project as it’s now starting to resemble a classic car! With this fresh layer of paint on, our beautiful Peony Red Jensen is blossoming into the iconic classic it should be.

Chris has been focusing on preparing other exterior elements for paint. Here Chris is working on a front bumper shield.

Our specialist paint technician, Chris, has been dedicated to preparing, masking and painting our beloved Peony Red Jensen. He began by applying primer and guide coat to the bonnet, panels and body. He then rubbed the car down with 320 and 500 sandpaper grit ready for paint. Once the car was masked up, it was ready for paint. Car masked up for a ‘Verkehrsgrau’ grey roof and red bottom. Once the two tones had been applied, Chris could paint on the clear preservative coat.

The Peony Red Jensen Is Almost Peony Red

Step by step, our Peony red 1960 541S Jensen gets closer to actually being Peony Red. We’ve been referring to it with its colour but its been nothing more than various shades of white or metal for quite a while. Soon, we’ll be able to honestly call it Peony Red.

Chris has been applying the guide coat onto the body and smoothing down all the surfaces, ready for it to be masked and painted.

The Jensen is now sat in primer and once dried, will be painted the infamous Peony Red.

Final Bits Before Paint On The Jensen

Our Peony Red Jensen is getting closer to actually be Peony Red. This classic Jensen has been sat in parts for a while as we work through the rust but is now on the final steps before it can be painted.

James has been working on creating a door spring mechanism that allows the window glass to sit safely inside the panel.

Below are some process photos of James preparing the door and fitting the elements. He’s been working on the left-hand door to remove old rust metal and tidy up repairs as well as fabricate new sections to weld in place.

Chris, our painter, has been preparing some of the individual elements for paint as the door wing and sill is now ready for primer. Several parts have been primed in a guide coat well as the wheels having been rubbed down ready for paint

Peony Red Jensen Bodywork Continues

Parts of our 1960 541S Jensen are sat in our paint bay whilst Chris works on them. The door hinges have been sandblasted, the door frames and door skins have been painted, and the boot, front bumper part and wheels are ready for primer. The black part for the boot rubber has also been painted.

Rust Bust On The Peony Red Jensen

The restoration to the Peony Red Jensen’s doors continues. James is working on correcting the corrosion damage by welding and fabricating new parts to replace the corroded elements. Both doors are bespoke and custom to the car, so James, one of our classic car specialists, is having to make all his adjustments bespoke and unique to the car.

You can see the process here:

Peony Red Bodywork

Our Peony Red Jensen has been masked and primed and is now ready for paint.

New Doors For Our Peony Jensen

Brian from our trim shop has been working on creating more interior fittings for our 1960 Peony Red Jensen 541S. The first steps in creating new door panels were to remove the old metal from the door panel board and make new panels from hardboard. The metal has been cut out and riveted, ready to be put in place. Brian then glued some foam to the door panel, cut out new leather and glued the sewn door panel to the leather panel. Once the parts were fixed together, Brian then turned the edges over. The next step was to then cut out the leather for the infill panel and glue that to the door panel.

A new armrest has also been fitted to the door panel. Brian removed the old cover from the armrest and made a new one, including new foam and a new pocket. Fresh piping has been fitted to the top edge of the pocket and foam support added. Chrome has then been added to the armrest trim.

Chris has removed the door skins from the door frames ready to have the paint taken off sandblasted. This is to combat the corrosion found inside the doors. Once this is completed, epoxy primer is applied inside and out. The bonnet and boot have been lined up and rubbed down as well. Holes have been marked out on the boot and are ready to re-drill.

James has removed both Aluminium door skins from the steel frames to work on the corrosion too. We will be using modern materials to avoid corrision occurring in the future rather than the original strips of canvas fabric to act as a barrier.

Here you can see the conditions of the door panels which are showing serious signs of corrosion and rust damage, including a series of holes appearing along the edge.

Peony Red Jensen Developments

Our 1960 Peony red Jensen 541S is making good progress in the workshop. Here are the latest developments.

Fabrication Bay

Our technician Chris has been working on the Jensen body in the fabrication bay. He’s been ‘gapping’ the doors so they look and fit the same around the sides. He’s also cut and ground both sides, added fibreglass to the bonnet to close the gap up and made a boot catch plate. Finally, Chris has marked the holes and tapping them up to make sure all the bolts fitted.

Trim Shop

Brian has been making a new door panel board from hardboard in the trim shop. This has been done by removing the armrest from the pocket section, removing the metal trim and old cover from the armrest and then making a new pattern for the cover.

Once a pattern has been made, Brian can cut it out from leather, sew on the new cover and fit it to the armrest by glueing and stapling it in place. Brian has also added metal trim to the armrest and cut leather out to make a pocket section. This was then glued in place.

The edges have been turned around to neaten the cover and new piping has been sewn in. Brian then needed to glue the inner metal to the foam, and fit the metal in place. The next step was to then glue the rest of the foam to the inner side of the pocket and fit the armrest to the pocket section. Once fitted, the armrest has been secured with screws and riveting support bar to the back.

Kath has also been working on the Jensen. She’s taken off the old cover from the dashboard and removed the old glue as well, ready to the rub down the front and back in preparation for new material.

Once cleaned down, Kath can mark out the new material and glue both surfaces to stick the material in place. To neaten it up, the material is turned over the edges and the dash holes are trimmed around so that the new cover sits comfortably. Once both sides were done and had followed the same process, Kath then glued along where the two pieces of material meet.

The dash top also needed to be refurbished. For this, Kath removed the two old covers and cut out new material ready to cover the dash top element. Once the material had been marked around the top, it could then be glued along one edge, the material turned over and the corners neatened up.

Lydia has also been working on the Peony Red Jensen interior. She’s been focusing on rear squab by measuring out all the leather, assembling the pieces together and sewing it all up. Lydia then prepared for the fitting of the cover on to the foam and board. She marked out new plywood to replace old worn out original. The next step was to then add wadding to the original foam so it maintains a nice shape. After all this was done, it was time to fit the cover over the squab.