Six years of work, hardly any usable result
Exceptionally, it wasn't a Mercedes-Benz from the greater Stuttgart area that arrived, but a 1962 Austin-Healey 3000 BJ7. The 2+2-seater had already had a lengthy restoration history, unfortunately not a successful one. A workshop in the owner's neighborhood had spent six years trying to work on the British classic. The result wasn't an advanced project, but rather an incomplete pile of parts, clumsy welding attempts, and a body that first needed to be brought back to a sound foundation.
Such cases are a bitter pill for owners to swallow. Six years of inactivity doesn't automatically mean six years of progress. If parts aren't documented, sheet metal is incorrectly fitted, and assemblies are stored unsorted, the actual restoration process later starts almost from scratch.
BJ7 with 2+2 body and 2.9-liter six-cylinder engine
The Austin-Healey 3000 BJ7 belongs to the second series of Big Healeys and was built in the early 1960s. Under the long hood sits the familiar 2.9-liter straight-six engine, producing around 132 hp in the BJ7. The 2+2 body style makes it more practical than the pure two-seaters, but it doesn't change the typical weaknesses of the series.
With a Healey, the condition of the bodywork determines the entire scope of the restoration from the outset. Sills, floor areas, doors, fenders, wheel arches, firewall, trunk floor, and the connections of the front body structure must all be sound. This particular vehicle also suffered front-end accident damage. A poorly repaired front end affects not only the appearance but also the hood fit, fender connections, and the geometry of the front components.
Poor welding attempts and damaged front end
The bodywork showed typical damage, but also signs of poor preparatory work. Rough welds, unclear transitions, and poorly prepared sheet metal areas are no small problem on an Austin-Healey. The bodywork is labor-intensive in any case, because many sections need to be fitted, straightened, and inspected in conjunction with the doors, hood, and fenders.
When exposing such areas, it quickly becomes apparent whether someone has replaced sheet metal or simply patched up the damage. If welds are poorly finished and filler is used to salvage the appearance, it's not the repair itself, but the paint preparation that ultimately creates the illusion. It won't last.
In the workshops in the Czech Republic, the bodywork was repaired, the front-end accident damage was fixed, and the base for the paintwork was prepared. This was followed by a complete paint job. The chassis was also installed so that the car could be returned to its owner in drivable condition.
A clearly defined project instead of an endless construction site
The order comprised a comprehensive restoration, excluding electrical work, engine work, and commissioning. The owner handled these aspects himself. This clearly defined the scope of work: bodywork, paint, chassis, and rollable superstructure were done by us, while final assembly of the remaining components was carried out outside our workshops.
From an economic standpoint, an Austin-Healey 3000 BJ7 is generally worth restoring. Demand for Big Healeys is stable, and a 1962 BJ7 with a 2.9-liter six-cylinder engine isn't one of those cars where you have to debate the merits of a serious bodywork over long. It only becomes risky if work has been done in the wrong places for the previous six years.
After the bodywork was repaired, repainted, and the chassis reassembled, the car was returned to its owner. A neighbor took over the final assembly. Hopefully, it won't take another six years this time. And hopefully, it will be more successful.
