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> Rebuiding Inside-out
bkrantz
post Aug 5 2020, 08:03 PM
Post #1061


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I made a first pass at cleaning the brain today, with some acetone.


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bkrantz
post Aug 5 2020, 08:04 PM
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That took off the black, but left the red (overspray, not the intentional Red).


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bkrantz
post Aug 6 2020, 07:50 PM
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A follow-up with progress on the brain box, after some careful application of paint remover.


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bkrantz
post Aug 6 2020, 07:52 PM
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The metal finish is still ugly. Not sure what to try next.


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bkrantz
post Aug 6 2020, 07:55 PM
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The relay board looks better. Soaking overnight in GoofOff dissolved most of the remaining tar. I have some leads on dielectric potting epoxy, to refill the board and re-insulate all the leads.


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bkrantz
post Aug 6 2020, 07:55 PM
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The top side also looks better.


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bkrantz
post Aug 6 2020, 07:58 PM
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Meanwhile, I have continued working on the main harness. I have identified and labeled all the plugs, leads, and components, and searched for more damage to repair. Got as far as the rear firewall. Still optimistic.


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bkrantz
post Aug 6 2020, 08:09 PM
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Posting this photo here so I can link it to the VIN database. The is the owners manual that came with my car (but obviously not the original).


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bkrantz
post Aug 6 2020, 08:10 PM
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And the next page.


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bkrantz
post Aug 7 2020, 08:41 PM
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Oh fudge! While sorting through more boxes of parts I found a section (actually 2 pieces) of engine sheet metal that I forgot. This is the front section.


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bkrantz
post Aug 7 2020, 08:43 PM
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I wanted to get this to the powder coating shop to include with all the other parts, and so quickly worked to straighten out some bends and dents, and weld one spot. I got to the shop just after 2:30, but they go home at 2pm on Friday.


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bkrantz
post Aug 8 2020, 08:54 PM
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Back at work on the wiring harness, and I completed my initial cleaning and survey. I think it generally looks good, with just local problems to fix. I have also identified all the connectors and have some sense of where everything goes.


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bkrantz
post Aug 8 2020, 08:57 PM
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I could not resist starting to fix things. Since I plan to move the fuel pump to the front I want to re-route and extend the existing wires. I started by pulling them from the branch tube that goes to the right side of the engine and battery.


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bkrantz
post Aug 8 2020, 08:58 PM
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I then used a length of welding wire to snake the pump wires through the snorkel and main tube.


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bkrantz
post Aug 8 2020, 09:00 PM
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Here are the pump wires, now reaching into the passenger compartment and heading "upstream".


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bkrantz
post Aug 8 2020, 09:01 PM
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I also worked on the tail light lenses. I was careless with the left one, and broke the lower corner of the reverse light end. Fortunately, I saved the chips.


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bkrantz
post Aug 8 2020, 09:03 PM
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I found some industrial acrylic welding fluid, that glues by partially dissolving the plastic.


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bkrantz
post Aug 8 2020, 09:05 PM
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I also found cracks around one of the stud bases. But easy to fix with small drops of weld fluid that wick into the cracks.


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bkrantz
post Aug 8 2020, 09:05 PM
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The corner looks rough from "below".


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bkrantz
post Aug 8 2020, 09:06 PM
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But pretty good in normal orientation.


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