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> Rebuiding Inside-out
bkrantz
post Oct 16 2019, 08:47 PM
Post #1


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I realize most rebuilds go from the inside to the outside, but I am struck by how straight and clean the outer panels, including paint, look on my 73 2.0. And all the nasty stuff is hidden underneath--which I know is also not unusual.

Any way, I bought the car knowing most of what it was: a 2.0 with all the sport and appearance group equipment, including 5 good Fuchs, and the original fuel injection. The original engine is confirmed by a COA. In contrast to the exterior the interior was mixed at best, with some funky carpet. And the front and rear trunks (and engine compartment, and interior) had been sprayed with black undercoating.

So after a month, I have the car stripped to a bare shell, except for suspension and steering. I measured everything I could, and the body is very square and on spec. I need to patch some local rust spots, and replace the rear floor. And then do some minor straightening: right headlight bucket, front edge of right front fender, rear panel, etc.


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bkrantz   Rebuiding Inside-out   Oct 16 2019, 08:47 PM
bkrantz   I forgot to mention that I will add some door brac...   Oct 16 2019, 08:49 PM
bkrantz   And I testing the Fein for cutting the floor sheet...   Oct 16 2019, 08:53 PM
Mikey914   Use the dry ice method if you need to remove more ...   Oct 16 2019, 09:31 PM
bkrantz   Been a couple of days and I have nearly completed ...   Oct 20 2019, 08:22 PM
raynekat   Been there, done that (or at least Cary who did al...   Oct 20 2019, 11:49 PM
bkrantz   Been there, done that (or at least Cary who did a...   Oct 21 2019, 08:20 PM
pploco   Use the dry ice method if you need to remove more...   Oct 21 2019, 08:31 AM
bbrock   The body plugs are important for separating the me...   Oct 21 2019, 08:50 PM
bkrantz   I have been out of town a bit, but needed to make ...   Oct 28 2019, 08:55 PM
bkrantz   I was waiting for a delivery truck, so decided to ...   Oct 28 2019, 09:01 PM
bkrantz   Cleaner cut for the rear trunk floor. Looks like ...   Nov 4 2019, 09:08 PM
Garland   Cleaner cut for the rear trunk floor. Looks like...   Nov 11 2019, 10:37 PM
bkrantz   Testing my spot weld drill bit.   Nov 5 2019, 09:34 PM
bkrantz   The bumpers, and all trim, were painted black. I ...   Nov 11 2019, 09:46 PM
bkrantz   Brought home a donor clip to use to replace my rig...   Nov 15 2019, 09:19 PM
bkrantz   Also a rear trunk lid, straighter than mine and wi...   Nov 15 2019, 09:20 PM
bkrantz   Starting surgery on the donor clip.   Nov 16 2019, 10:08 PM
Superhawk996   Watching this build. Keep going! :cheer:   Nov 17 2019, 12:22 PM
bkrantz   Cut the donor clip down more. This is the largest...   Nov 17 2019, 10:21 PM
bkrantz   Started surgery on the receiver car. Removed the ...   Nov 18 2019, 09:34 PM
bkrantz   Here are the parts removed. I will reuse the circ...   Nov 18 2019, 09:35 PM
bbrock   Are you still using your Fein for the cutting? Th...   Nov 18 2019, 09:51 PM
bkrantz   The Fein works best where I can cut from an expose...   Nov 19 2019, 09:19 PM
bkrantz   First pass at reforming the floor corner.   Nov 19 2019, 09:21 PM
bkrantz   And progress on the rear, removing the rear panel ...   Nov 19 2019, 09:24 PM
bkrantz   Left corner detail. Pretty nasty work done when t...   Nov 19 2019, 09:25 PM
bkrantz   Quick adjustments of the inner fender corners, lef...   Nov 20 2019, 05:45 PM
bkrantz   and right:   Nov 20 2019, 05:45 PM
bkrantz   Now the panel fits.   Nov 20 2019, 05:46 PM
bkrantz   Back at the front, I am probably done working the ...   Nov 20 2019, 05:48 PM
bkrantz   And started to dissect the donor clip. All I need...   Nov 20 2019, 05:51 PM
bkrantz   Here's how the front corner started. I feel p...   Nov 20 2019, 05:56 PM
FourBlades   Some great progress! :trophy: Nice work...   Nov 20 2019, 05:57 PM
jim_hoyland   Impressive ! :) :beer1:   Nov 20 2019, 06:05 PM
bbrock   :worship: Nice work!   Nov 20 2019, 09:41 PM
bkrantz   Thanks, everyone. Donor part down to inner fender...   Nov 21 2019, 09:51 PM
raynekat   Looking good there Bob.   Nov 22 2019, 12:31 AM
bkrantz   Thanks, Doug. I am in deeper than I wanted, but k...   Nov 22 2019, 09:21 PM
Cairo94507   Nice work and skills. :beer2:   Nov 23 2019, 08:17 AM
bkrantz   After a long trip to Tucson for turkey and visitin...   Dec 5 2019, 09:15 PM
bkrantz   More work to do on the right end of the front pane...   Dec 5 2019, 09:18 PM
GTSandberg   Craftmanship and attention to details, Im in :pop...   Dec 6 2019, 06:13 AM
bkrantz   Still working the fit. Made a cardboard template ...   Dec 7 2019, 09:37 PM
bkrantz   Work to do. Gap seen from below.   Dec 7 2019, 09:38 PM
FourBlades   Looking good! Do some diagonal measurements f...   Dec 8 2019, 11:26 AM
bkrantz   Looking good! Do some diagonal measurements ...   Dec 8 2019, 09:35 PM
bkrantz   More metal work, and the fit is getting closer--of...   Dec 8 2019, 09:37 PM
bkrantz   Last bit of mis-alignment is the outermost end of ...   Dec 8 2019, 09:42 PM
bkrantz   After a few more hours today, I am claiming victor...   Dec 9 2019, 09:16 PM
bkrantz   Of course, I might tap on things a bit more, just ...   Dec 9 2019, 09:17 PM
bkrantz   Now starting on the rear. Weeks ago, I cut out th...   Dec 10 2019, 09:45 PM
bkrantz   And here is the lumpy right side. Previous repair...   Dec 10 2019, 09:47 PM
bkrantz   First effort, left side. Almost good.   Dec 11 2019, 08:38 PM
bkrantz   And right side. Still needs work.   Dec 11 2019, 08:40 PM
bbrock   You are a wizard. :worship:   Dec 11 2019, 09:19 PM
bkrantz   Right side done enough for now.   Dec 12 2019, 10:40 PM
bkrantz   Time to start on the rear panel. And yes, almost ...   Dec 12 2019, 10:43 PM
bkrantz   Getting back to work, and a real milestone today: ...   Dec 17 2019, 09:05 PM
bkrantz   And the first parts of the bracing for the open bo...   Dec 17 2019, 09:08 PM
bkrantz   Completed the interior bracing with some diagonals...   Dec 22 2019, 09:27 PM
bkrantz   And completed the patches on the right front inner...   Dec 22 2019, 09:29 PM
bkrantz   Two steps forward, at least one back! I knew ...   Dec 22 2019, 09:32 PM
bkrantz   Decided to separate, in order to make it right. T...   Dec 22 2019, 09:35 PM
Superhawk996   :Qarl: Yea! Coming along nicely. Saw you...   Dec 23 2019, 02:50 AM
bkrantz   :Qarl: Yea! Coming along nicely. Saw yo...   Dec 23 2019, 09:27 PM
bkrantz   Here's the front corner mostly welded in place...   Dec 23 2019, 09:29 PM
bkrantz   Meanwhile, getting started on the rear. First tri...   Dec 23 2019, 09:32 PM
bkrantz   And starting the fit for the rear panel. This wil...   Dec 23 2019, 09:34 PM
bkrantz   Right side is looking better, with access after re...   Dec 23 2019, 09:35 PM
djway   AWESOME There has got to be some Satisfaction ther...   Dec 23 2019, 10:49 PM
bkrantz   AWESOME There has got to be some Satisfaction the...   Dec 24 2019, 09:56 PM
sixnotfour   :agree: :smash: :welder: :beer2:   Dec 23 2019, 11:09 PM
bkrantz   Got the outer fender cut and fit. A few more twea...   Dec 24 2019, 09:58 PM
bkrantz   And...here's the last dodgy previous repair, w...   Dec 24 2019, 10:00 PM
bkrantz   Only a half-day for xmas, since I want to get as m...   Dec 25 2019, 09:16 PM
bkrantz   And a further adjustment and test fit for all the ...   Dec 25 2019, 09:21 PM
Superhawk996   :trophy: Looking better. My car has been clip...   Dec 26 2019, 09:19 AM
bkrantz   :trophy: Looking better. My car has been cli...   Dec 26 2019, 09:07 PM
bkrantz   Got the rear panel and outer fender welds mostly d...   Dec 26 2019, 09:09 PM
bkrantz   Left side needed a 3/4 inch wide filler for the ga...   Dec 26 2019, 09:11 PM
bkrantz   Same on the right side, but the gap was only 3/16 ...   Dec 26 2019, 09:12 PM
bkrantz   And what was the lap joint in the front panel, now...   Dec 26 2019, 09:14 PM
FourBlades   Nice work! :first: Great to fix things the...   Dec 27 2019, 09:47 AM
bkrantz   Nice work! :first: Great to fix things th...   Dec 27 2019, 09:48 PM
bkrantz   Getting the front seam stitched up, along with the...   Dec 27 2019, 09:52 PM
bkrantz   Here are the accessory pieces I made for the rear:...   Dec 27 2019, 09:57 PM
Kansas 914   Bob - you are doing everything right. It was nic...   Dec 28 2019, 06:29 AM
FourBlades   What are the reinforcement pieces for? John   Dec 28 2019, 08:28 AM
bkrantz   John, the 1/8 inch thick L-braces are for the bump...   Dec 28 2019, 09:45 PM
bkrantz   Got the trunk floor welded in, with plug welds all...   Dec 28 2019, 09:48 PM
bkrantz   Lower bumper mount hole reinforcement, using 1/8 i...   Dec 28 2019, 09:50 PM
bkrantz   And my own additional brace for the upper bumper m...   Dec 28 2019, 09:51 PM
bkrantz   And a simple bent strip to bridge the gap between ...   Dec 28 2019, 09:54 PM
bkrantz   Now the fun part: fabricating brackets from 2 inch...   Dec 28 2019, 09:57 PM
bkrantz   And the front, where greater curvature requires lo...   Dec 28 2019, 09:58 PM
bkrantz   Here's the rear, with the horizontal mount fro...   Dec 28 2019, 09:59 PM
bkrantz   Finally! The car is on the rotisserie lift. ...   Dec 28 2019, 10:02 PM
ndfrigi   wow @bkrantz you and your son are doing a lot of...   Dec 28 2019, 10:10 PM
bkrantz   Final steps. First, we detached the suspension--t...   Dec 29 2019, 10:03 PM
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