Fearless Cruisers
The JournalSample article

2 August 2026 · 5 min read

The Anatomy of a Bare-Metal Restoration

Rebuilt 2F engine bay of a restored FJ40

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A bare-metal restoration is exactly what it sounds like. The body comes off, the chassis is stripped and blasted, and every bracket, line and fastener is renewed or replaced. It is slow, deliberate work, and it is the only way to be certain of what lies beneath the paint.

Start at the chassis

We blast and powder-coat the chassis before anything else goes back on. New brake lines, fuel lines and a new fuel tank follow. Only once the foundation is sound do we turn to the engine, the gearbox and the interior.

Front suspension detail of a restored FJ40
Bilstein shocks, fitted during reassembly.

The engine is stripped, inspected and compression tested, then rebuilt with new gaskets and fluids throughout. It is unglamorous work that never shows in a photograph, and it is the difference between a car that looks restored and one that truly is.