A Texas Sized Project - 1975 2.0L, 12/8/20 - Wiring & Interior Update Options

[Mueller]

Awesome amount of work, it looks great. The "next" owner of my car can do all that work, mine will never be torn down to that level and I'm okay with it (IMG:style_emoticons/default/smile.gif)

[aggiezig]

Well, it was a productive weekend for us! Progress was slow as usual, but the front trunk and cabin are in Mexico Blue and that is a big step forward. No, it's not show quality paint but I think it looks pretty great for parts of the car that will never be seen.

Before I could lay any paint, there were a few things to attend to besides scuffing and cleaning. One of those tasks was reinforcing the front trunk pull area. When stripping paint, we noticed rust around this area that led to a couple of holes. After trying to fill the holes with mig wire, I had no luck. I decided the best course of action was to put a doubler in place to strengthen the area. After securing it in place using plug welds, I seam sealed over the patch to hide it.

(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-19557-1522078426.1.jpg)

(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-19557-1522078426.2.jpg)

We built the canopy to try to keep the wind and pollen out. It was a beautiful day but the wind was blowing pretty good. After pushing the car under the tent, I gave everything a final wipe down. One thing that I didn’t plan on was that the wax & grease remover I've been using (shopline) started to soften the seam sealer. This made things messy when I was trying to prep for paint. I'm not sure if the seam sealer didn't have enough dry time (3-4 days) or if it's permanently soluble. At any rate, I cleaned the best I could with that obstacle and while trying not to wipe off too much sealer in the process.

(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-19557-1522078427.3.jpg)

(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-19557-1522078427.4.jpg)

Next up was paint. I'm using PPG Concept DCC Single Stage paint in Mexico Blue. It's a 4:2:1 (base : reducer : hardener) with the activator I purchased (DCX61). I tried to spray some of the tighter areas with my touch up gun first, but ended up just using my full size gun for almost everything. I sprayed using a Devilbiss Starting Line gun at 28-30 PSI or so with a 1.3mm tip. First I laid down a lighter but full coat and then followed up with a medium-heavy wet coat. The only place that didn't receive two coats were the floor panels as they will be completely covered.

(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-19557-1522078427.5.jpg)

(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-19557-1522078427.6.jpg)

(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-19557-1522078428.7.jpg)

(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-19557-1522078428.8.jpg)

I'm really impressed with this DCC paint - the color is deep and the gloss is outstanding. With proper prep work, this paint is going to really stun on the outside of the car. These areas that I shot look good enough for what they are. The finish definitely isn't perfect and there was obviously plenty flying around in the air when I was spraying and there are some fuzzies in the finish. I only put a couple of coats on so I don't think it's enough to color sand and buff nor do I think it'd be worth the effort. Because all of this is under hoods or carpet and covered up, I'm not too worried about it.

(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-19557-1522078428.9.jpg)

(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-19557-1522078428.10.jpg)

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(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-19557-1522078429.12.jpg)

There is one area that I will have to sand and re-coat because of solvent pop. I'm not really sure what happened here as it's the only place with this issue. I was using a slower reducer than probably was needed and this may have led to the issue, but again it only occurred in one spot on the driver side fender top.

(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-19557-1522078429.13.jpg)

I think I'm going to let the paint sit for a week or so and gas off before I wrap everything up in plastic to keep it from getting dirty or damaged. I still have to spray the engine bay and the rear trunk but I think I may take a slight detour and work on getting hoods and doors in epoxy primer first as they are still sitting in bare metal after being stripped. I'm really hoping (and needing) to see this car in color over the summer, so this is a good push in that direction. Thanks for reading so far and thanks for all of the encouraging words!

[bbrock]

Lordy that's blue!!! That is going to look fantastic. Good to know you liked the Concept DCC, that's probably what I'm going to spray on my interior areas. Keep up the great work. (IMG:style_emoticons/default/smilie_pokal.gif)

[jesse7flying]

Man, that is looking really good. That DCC is pretty expensive isn't it? Can't wait to see color on the outside.

[914Sixer]

Mexico Blue (IMG:style_emoticons/default/aktion035.gif)

[aggiezig]

Man, that is looking really good. That DCC is pretty expensive isn't it? Can't wait to see color on the outside.

It's great stuff but yes, very expensive. A gallon plus reducer & activator ran me $700+. It's really great stuff and easy enough for a novice like me.

----

I started cleaning up the remaining paint on the trunk lids tonight after work so I can get them covered in epoxy primer. Unfortunately, it looks like more rust repair on the rear trunk lid. Why did the folks at Porsche put open cell foam inside of these lids...

(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-19557-1522117710.1.jpg)

(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-19557-1522117710.2.jpg)

(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-19557-1522117711.3.jpg)

I really don't want to, but I think the best course of action is to cut a section open to clean out the foam and rust treat. Then seam weld it back in place. Not going to be fun... But I don't really think I have another option. Hopefully there isn't any foam in the front trunk lid...

[aggiezig]

Alright, I made the plunge and cut into the trunk lid. There was a lot of pitting, deeper than I expected where the foam sandwiched the metal. It can be saved, but still a major PITA.

Cut lines laid out:
(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-19557-1522296236.1.jpg)

Revealing the rust underneath:
(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-19557-1522296237.2.jpg)

After lots of clean up and chemical rust conversion:
(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-19557-1522296238.3.jpg)

Looking down the framework:
(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-19557-1522296239.4.jpg)

(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-19557-1522296239.5.jpg)

Filling some smaller holes with mig wire. I think the larger one will need a patch.
(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-19557-1522296240.6.jpg)

And finally, coated with Master Series rust encapsulator:
(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-19557-1522296262.1.jpg)

I'm going to take a break here before tackling the other half. The rust is much worse on the bottom half and I really hope I don't end up making compound curve patches for such a small area. We'll find out soon. Anyone know if the front trunk lid also has foam in it?

[Cairo94507]

That is a beautiful color. Nice work and you will love the finished project. Rust hides everywhere on these old babies. Glad you are addressing it now. It would surely rear its ugly head in a couple years otherwise. (IMG:style_emoticons/default/beerchug.gif)

[aggiezig]

Small update, but was able to finish blasting everything that was once Malaga Red.

(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-19557-1522960890.1.jpg)

Of course, in the process I found some more rust...

(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-19557-1522960891.2.jpg)

(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-19557-1522960892.3.jpg)

These will be fun to fix because 1) I'll have to re-create that c-channel by hand and 2) some of the rust is in spots that are double layered.

(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-19557-1522960892.4.jpg)

While I was at it, I also coated the trunks in master series primer. I decided to put this down under the epoxy because of the spots of rust on the trunk skins (I don't want it to break through the epoxy even though it was treated). I also found some oil-canning on the rear trunk lid that will need fixing. Gonna be fun...

[aggiezig]

Okay, spent a decent amount of time on the teener this weekend and have some progress to report. The rust in the bottom of the door seal track has been repaired. I used a copper spoon and filled with MIG wire. Concours guys would probably cut out and weld back in a new channel, but I blasted and treated the rust before welding so we should be good.

(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-19557-1523248004.1.jpg)

(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-19557-1523248004.2.jpg)

I cut out the areas that were completely rusted through on the bottom of the door and replaced with new 18ga metal. The original metal here is double walled but my replacement is just one piece. Again, not concours but looks great and no one will see the difference, especially after the seal is in place. After the repairs, I treated with master series and then seam sealed.

(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-19557-1523248005.3.jpg)

(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-19557-1523248005.4.jpg)

Lastly, I prepped and cleaned the doors and engine decklid and got everything in some epoxy primer. Today just the back sides and tomorrow will likely do the fronts.

(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-19557-1523248006.5.jpg)

(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-19557-1523248006.6.jpg)

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(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-19557-1523248007.8.jpg)

Progress, progress, progress. I'm moving to the West Coast this Fall, so I'm extremely motivated to have this thing in paint and on its own wheels before I move in September.

[Cairo94507]

Nice progress. At the rate you are moving, your goal seems reasonable and attainable. (IMG:style_emoticons/default/beerchug.gif)

[aggiezig]

Nice progress. At the rate you are moving, your goal seems reasonable and attainable. (IMG:style_emoticons/default/beerchug.gif)

Thank you, I hope you are right!

-------------

I have a little more progress to report. I was able to get the top sides of the doors and decklid painted in epoxy. While the epoxy was still glossy and curing, it was a good chance to scope out the state of the panels and track down all of the dents and waves. There are a couple of decently large dents and lots of little ones. I'll see if I can pull the big ones but the little ones will likely be filled. I'm no metal man and as long as I'm not laying on the filler too thick, I think everything should work out ok.

(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-19557-1523595219.1.jpg)

(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-19557-1523595220.2.jpg)

(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-19557-1523595220.3.jpg)

(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-19557-1523595500.1.jpg)

I also started working on the front hood. First some guide coat to see what I was working with. This revealed a lot of lows and I ended up finding an area that wasn't quite oil-canning but on its way there. I pulled out the torch and got to shrinking as best as I know how (heat, hammer, quench). After an hour or so I had it to a point where there was no more flex and only some minor valleys that could be filled.

(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-19557-1523595220.4.jpg)

(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-19557-1523595220.5.jpg)


So, next was a coat of Evercoat Rage Extreme over the whole panel. I let this cure overnight and today after work started blocking the panel down. I roughed it up using an air inline sander and then pulled out the 24" durablock and some 80 grit. Here's where I stopped for the night. I'm starting to see the beginning of some "metal islands" so only a little more blocking to go before re-applying filler in a couple of low spots. Overall, the panel is really shaping up with this first coat and block. I was thinking I'd need to follow up with polyester but honestly might skip straight to 2k after blocking the filler smooth.

(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-19557-1523595221.6.jpg)

(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-19557-1523595221.7.jpg)

(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-19557-1523595221.8.jpg)

While I've been working away on the body, my mind's been racing forward thinking about everything I'm going to need to get the car back on its own wheels after paint. Unfortunately, it sounds like about $1500 worth of new parts.... shocks, ball joints, bushings, bearings, rebuilt calipers, etc. It amazes me the cost of some of these P-car parts.

I've also been thinking about the hardware I'm going to need. I've already started tumbling and stripping back hardware. At this point I think I have everything set aside that I'll need to get re-plated. I'm having a hard time finding a shop that will even both returning my emails or calls. I think a lot of operations are pretty picky about what type of jobs they take on. Hopefully I can find someone soon-ish and have work started on that element of the rebuild.

[KBMAN]

(IMG:style_emoticons/default/aktion035.gif) wow, that is really amazing....looking at the beginning pics, I was thinking to myself, 'who would want to fix THAT?' But I tip my hat to you guys, and what lovely work you are doing to that 'Smurfet'...JOB WELL DONE SO FAR

[autopro]

Man great job on your car and on this thread, it's great you are providing all the details of the tools, products and procedures you are using. It really makes it easy for others to do the same. Awesome (IMG:style_emoticons/default/beerchug.gif)

[aggiezig]

Appreciate the feedback!

I took another look at the rear trunk lid section that I cut out. It was really toasty. I thought about making a patch panel but with the complex shape, I just don't think I have the metal working skills to make it look right. So I decided the next best thing would be to repair the OG piece. I cut some 18ga steel to act as a patch behind the holes. This way there would be structure behind the holes when I try to fill them with mig wire. In all honesty, it worked out pretty well and will be hidden. I just need to finish grinding everything down.

(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-19557-1524499887.1.jpg)

(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-19557-1524499887.2.jpg)

I'm still chugging away on bodywork over here... I skimmed both doors and started blocking down the passenger door. I'm using evercoat rage extreme. It spreads a lot easier if you thin it down some with "plastik honey" which can be bought on amazon. I switched to thin metal spreaders and they are way easier to work with than plastic spreaders. After using, they clean up really nicely with just a bit of thinner.

(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-19557-1524499888.3.jpg)

(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-19557-1524499888.4.jpg)

I start by using my air sander to rough level the filler, then move on to the durablock and hand blocking. On the doors I didn't go for the big 24" durablock because of the size of the panel and curve. Instead, I used a smaller block and some 80 grit to shape. This Evercoat Rage Extreme feathers out pretty nicely.

(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-19557-1524499888.5.jpg)

I tried to fill the void between the crash bar and the door skin with 3M flexible foam. The idea is to provide something to keep the door skin from flexing while still allowing for movement as the metal expands and contracts. I splurged and bought the fancy gun and all but this stuff was still a pain in the a$$. The foam is a 2-part mix and it was hardening in the tip before it could reach the end. I'm talking mere seconds. I tried using two different tips before giving up. Basically I ended up having to mix on some cardboard and spread with a bondo spreader. It's messy but will be hidden.

(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-19557-1524499888.6.jpg)

(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-19557-1524499888.7.jpg)

Cleaned & ready for 2K

(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-19557-1524499889.8.jpg)

(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-19557-1524499889.9.jpg)

(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-19557-1524499889.10.jpg)

I also sprayed epoxy and 2K on the front trunk lid hood. My goal is to get the filler work done and everything in primer before moving on.

[aggiezig]

I finally got back around to stitching the trunk lid back together. It's not pretty but it's there. I was fighting crappy metal the whole time so ended up using more mig wire than one would hope. Good news is you'll never know the difference after I grind it all down:

(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-19557-1524671243.1.jpg)

I am in a little over my head with the rear trunk lid. There is a decent amount of flex in the middle of the skin where there is no support structure underneath. From what I can tell, it's very straight and doesn't ever look like it was dented or hit. However, if you push anywhere in the upper middle section of the trunk lid you can get the metal to flex. I'm scared to try to shrink anything here as it's a huge section and I don't think I have the skillset to fix it without toasting the piece. Will have to do more research.

Also, finished up with the driver's door. About 90% of the filler ended up on the ground and just a skim coat was left. I prepped the headlight covers too and shot everything with 2k:

(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-19557-1524671244.2.jpg)

(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-19557-1524671245.3.jpg)

Not sure where I'm going to turn next. I've continued to work on cleaning up and stripping parts for plating. I tried to disassembly my calipers over the weekend with some luck, but a lot of frustration. I will probably take another look at these and see if I can't get everything together for plating.

I also found an issue with the epoxy primer on the engine decklid. There are some areas of bubbling in paint, and I think it's from the wax & grease remover I've been using that was still on the panel when I sprayed. I'm going to have to strip and re-spray that panel before it can continue. Nothing like doing something over again.

One of these days I will finish the seam sealer in the engine bay and prep the rear trunk for blue paint. It would be nice to have all of that done and sealed off while shaping and sanding the exterior body.

[aggiezig]

I keep chugging along over here, slowly but surely. It's taking a lot longer to clean up and prep hardware for plating than I thought it would. First, everything is soaked in degreaser for a day or two. Then, smaller parts are tumbled. Next, I drop everything in diluted muriatic acid (about 10-15% HCL) for a quick pickle. Lastly, I coat everything with WD-40 to ward off the flash rust. The problem is, I keep finding more hardware to clean!

Here's a bucket of parts after acid dip and WD40.
(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-19557-1525109113.1.jpg)

Here are some of my parts laid out. I have a lot of duplicates thanks to the parts car I disassembled last year. Might as well re-plate everything.
(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-19557-1525109114.2.jpg)

I still need to finish cleaning up the brake caliper halves so that they can be plated at the same time. I'm hoping to get everything sent out this week to the platers. We'll see if I'm that lucky.

It looks like someone had shut the hood on tools before, so I had a small area to pull & fill on the underside of the front hood:
(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-19557-1525109114.3.jpg)

(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-19557-1525109116.4.jpg)

Then a coat of epoxy primer to seal it in while it sits until everything else is ready:
(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-19557-1525109117.5.jpg)

(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-19557-1525109118.6.jpg)

The rear hood is still on pause until I can talk with someone who has more metalworking experience than me about the skin flex. Now that most of the removable pieces are in 2K, I will probably try to shoot some polyester on the body and start blocking. I'd really like to be spraying color in June, we'll see if I'm that lucky.

[aggiezig]

It was a productive weekend over here. I picked away at all sorts of small things and made a decent amount of progress. Last week I pulled a few pieces out of the attic that would need to be prepped for paint including: the fuel tank, the rocker covers, and the front / rear bumper chin valence pieces.

First up was the fuel tank. I tried using the chemicals included with the KBS coating kit to remove the rust in the tank but no luck. It was built up pretty good so I ended up setting up the tank for electrolysis rust removal. I used washing soda for my salt and a piece of square tubing as an anode. I let it run all weekend and the tank is much cleaner inside now.

(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-19557-1525664372.1.jpg)

I also worked the dents out of the rocker covers and bumper chins and stripped them down to bare metal. No pics right now, but will take some once they are in primer. I think I am going to paint them in either raptorliner black or SEM chip guard.

You may recall that the PO cut my dash in half for some reason. So I worked on fixing that, too.

(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-19557-1525664373.2.jpg)

(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-19557-1525664375.3.jpg)

Finally finished cleaning and sorting parts and everything is boxed up to go to the plater in Dallas. This is one of (3) large USPS flat rate boxes.

(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-19557-1525664375.4.jpg)

Threw a coat of SEM trim black on these u-joints:

(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-19557-1525664376.5.jpg)

Lastly, I finished shaping the body filler on the driver front and rear quarters. Because I sanded through the epoxy, I decided to put another thin coat on. This made for a really good opportunity to wet check the quarters before applying polyester primer.

(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-19557-1525664377.6.jpg)

(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-19557-1525664378.7.jpg)

Looking good so far. After the epoxy flashed, I sprayed three wet coats of Evercoat Feather Fill G2, un-thinned. This is a polyester primer filler that will be a great base for me to do all of my blocking on to take care of the small imperfections that weren't worth body filler.

(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-19557-1525664378.8.jpg)

I'm going to try to get the driver's quarters in poly primer this week as well. In hindsight, I don't think I would tackle paint and body work in stages like I have been so far. Yes, it's helpful to keep motivated and see progress. But, I spend a sh*t ton of time masking, cleaning, and re-doing things because everything is sectioned off in different stages. Oh well, live and learn.

More to come, soon!

[TravisNeff]

Great thread!

[bbrock]

Great progress. Thanks for the insight on staging the paint job. As I inch slowly toward painting my car, I've been wondering about how to approach this. I really appreciate you sharing your experience.

BTW, do you remember roughly what it cost to have your Raptor bedliner tinted? I'm leaning in that direction but haven't decided.