1960 Ford Thames 300E – A Masterclass in Custom Engineering, Restoration, and V8 Performance

The 1960 Ford Thames 300E is one of the most recognisable light commercial vehicles of post-war Britain. Originally designed as a practical workhorse for tradesmen and small businesses, it has since become a cult classic among Ford enthusiasts and custom builders.

While most surviving examples are restored to factory specification, this particular Thames 300E has been transformed into something entirely different – a full ground-up, race-inspired restomod that blends classic British styling with American V8 muscle and modern motorsport engineering.

This is not simply a restoration. It is a complete re-engineering of a historic vehicle, built with no compromise in performance, safety, or craftsmanship.

The Foundation – A True 1960 Ford Thames 300E

The project began with an authentic 1960 Ford Thames 300E 7cwt panel van, originally built by Briggs Motor Bodies in Doncaster. These vans were known for their durability and simplicity, but after decades of use, most surviving examples suffer from severe corrosion and structural fatigue.

This particular vehicle was no exception.

The restoration process started with a full strip-down to bare metal. Seven layers of paint were carefully removed, revealing the original beige factory finish beneath. Once exposed, the body was shot blasted to reveal the true condition of the steelwork.

What followed was a full structural rebuild.

Extensive Body Reconstruction – Built, Not Repaired

The level of corrosion meant that simple patch repairs were not an option. Instead, large sections of the body were completely rebuilt using new steel fabrication.

Key restoration work included:

• Replacement of the lower six inches of the entire body shell
• New sills fabricated and aligned for structural integrity
• Rebuilt rear valance and rear wheel arches
• New gutters and side panels hand-formed in steel
• Front valance fully replaced and reshaped

To ensure long-term durability, a completely new internal structure was also fabricated:

• Hand-built bulkhead in 18-gauge mild steel
• Custom dashboard construction
• Fully fabricated transmission tunnel
• New steel flooring throughout the cabin

In addition, the rear wheel tubs were reshaped and strengthened, and a removable steel fuel tank cover was engineered for service access.

Even the bonnet was reimagined, fitted with custom rear hinges to improve engine bay access and usability.

Despite the extensive modifications, original styling elements were carefully preserved, including:

• Chrome Ford badges
• Original grille and bumpers
• Period-correct lighting
• Rare Enfo windscreen

This balance between preservation and fabrication ensures the van retains its unmistakable classic identity.

Race-Built Chassis and Structural Reinforcement

Rather than relying on the original ladder frame, the decision was made to engineer a completely bespoke chassis designed for high-performance use.

The chassis and structural system were built by Adrenalin Race & Performance in Northamptonshire, specialists in motorsport fabrication.

Constructed from heavy-duty 3” x 2” mild steel box section, the chassis provides extreme rigidity and safety. It also integrates a Hauser Racing rear section, designed specifically for high-power applications and drag-style load transfer.

A full CDS steel roll cage was incorporated into the structure, built to a 7.5-second drag racing specification. This level of reinforcement ensures:

• Maximum torsional rigidity
• Driver protection under extreme load
• Integration of drivetrain and suspension mounting points
• Structural support for high horsepower operation

This effectively transforms the Thames 300E from a classic van into a purpose-built performance platform.

Chevrolet V8 Power – The Heart of the Build

At the core of this project lies a 350 cubic inch (5.7-litre) Goodwrench small block Chevrolet V8 crate engine.

Chosen for its reliability, torque delivery, and tuning potential, this engine provides the perfect balance of street usability and high-performance capability.

Engine specification includes:

• Offenhauser dual-plane inlet manifold for improved airflow
• Edelbrock 600cfm carburettor for precise fuel delivery
• High-performance HEI ignition system for strong spark reliability
• Competition-grade nitrous oxide injection system for additional power on demand

This combination delivers strong low-end torque, rapid throttle response, and the ability to dramatically increase performance when required.

Transmission and Drivetrain Engineering

Power is transferred through a rebuilt GM TH350 three-speed automatic transmission, a proven unit known for strength and durability.

Upgrades include:

• Hughes Performance high-stall torque converter
• B&M Quick Silver ratchet shifter for precise gear selection
• Moroso transmission cooler for thermal stability
• Internal performance enhancements for increased load capacity

The drivetrain is designed to handle both street driving and high-performance use without compromise.

Advanced Suspension and Handling System

To match the power output, the suspension system has been completely re-engineered.

Rear Setup:

• Jaguar Mk2 3.8-litre rear axle
• Thornton Powr-Lok limited-slip differential
• Narrowed axle housing for correct track width
• Custom driveshafts
• Adjustable four-link suspension system
• Protech coil-over dampers for tuning capability

Front Setup:

• Fabricated tubular lower control arms
• Ford Capri Mk3 struts rebuilt and upgraded by Leda
• Adjustable Eibach coil springs
• Billet alloy hubs by Chris Isaac Race Cars

This setup provides modern handling characteristics while maintaining a classic vehicle footprint.

Precision Steering System

Steering is handled by a chromed Flaming River rack-and-pinion system, converted for left-hand drive configuration.

Additional components include:

• Custom steering arms for geometry correction
• Modified Triumph 2000 steering column
• Precision alignment for improved road feedback

The result is a steering system that is far more responsive and accurate than anything the original van could have offered.

High-Performance Braking System

With significant power comes the need for serious stopping capability.

The braking system includes:

• Wilwood four-piston calipers front and rear
• Ford Capri front discs
• Jaguar rear disc setup
• Wilwood adjustable proportioning valve
• Hurst roll control system
• Stainless steel braided brake lines
• Fully custom pedal assembly

This ensures consistent braking performance under both road and performance conditions.

Cooling, Fuel, and Exhaust Systems

Cooling System:

• Meziere electric water pump
• Custom four-row aluminium radiator
• SPAL high-performance cooling fan
• Aeroquip fittings throughout

Fuel System:

• Dual Facet electric fuel pumps
• Holley fuel pressure regulators
• Dedicated nitrous fuel delivery system
• Custom-fabricated aluminium fuel tank

Exhaust System:

• Hand-built tubular headers
• 3-inch polished exhaust system
• Magnaflow silencers for controlled flow
• Stainless Summit tailpipes

The exhaust note delivers the unmistakable deep rumble of a classic American V8.

Fully Engineered Electrical System

The electrical system is one of the most meticulously designed aspects of the build.

Every wire is:

• Individually numbered
• Soldered and heat-shrunk
• Fully documented in a dedicated wiring manual

Key features include:

• Twin marine-grade fuse boxes
• Auto Meter performance gauges
• Overhead control panel system
• Remote central locking
• Integrated warning and safety systems
• Dedicated nitrous control interface

This level of organisation ensures reliability, serviceability, and long-term durability.

Exterior Finish – Muscle Meets Classic Britain

Once fabrication was complete, the van was refinished in a striking Muscle Machines Orange two-pack acrylic paint, giving it a bold and aggressive visual identity.

Finishing details include:

• Hand-painted signwriting
• Gold leaf detailing for a period-correct custom look
• Polished chrome trim and original styling elements

The result is a perfect fusion of vintage commercial design and American hot rod influence.

Interior – Luxury Meets Motorsport

Inside, the cabin has been completely reimagined for comfort, style, and performance usability.

Interior features include:

• Premium Newmarket Premiere leather upholstery
• Custom upholstered steering wheel
• Bespoke centre console and door panels
• Fully trimmed headlining and roll cage padding
• Sound-deadening insulation throughout
• Premium wool carpeting
• JVC audio system integration

Every surface has been carefully designed to elevate the driving experience while maintaining a motorsport-inspired aesthetic.

Conclusion – A One-of-One Engineering Achievement

This 1960 Ford Thames 300E is far more than a restored classic van. It is a complete reinvention of a British icon, combining:

• Hand-built fabrication
• Race-grade chassis engineering
• American V8 performance
• Modern suspension and braking systems
• Bespoke luxury interior craftsmanship

The result is a truly unique machine that respects its heritage while completely redefining what a classic commercial vehicle can become.

It stands today as one of the most extreme and impressive Ford Thames 300E builds ever created – a perfect fusion of history, innovation, and raw performance.

Follow this unique Build on Instagram @jon_gurney65

Also featured in Custom Car Magazine and published on YouTube by SuperFly Autos™ Magazine.