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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 remembered the cover for under the steering rack...   Jul 25 2020, 08:27 PM
bkrantz   I think I am addicted to metal work. I enjoyed an...   Jul 25 2020, 08:30 PM
bkrantz   And not much paint on yours, too.   Jul 26 2020, 08:50 PM
bkrantz   A bit of welding and grinding today, to finish up ...   Jul 26 2020, 08:52 PM
bkrantz   And then one more round of hammer work and straigh...   Jul 26 2020, 08:53 PM
bkrantz   With the table cleared, I got back to electrical w...   Jul 28 2020, 08:53 PM
bkrantz   This might be the original unit.   Jul 28 2020, 08:53 PM
bkrantz   I pulled the rear cover. Pretty nasty.   Jul 28 2020, 08:54 PM
bkrantz   Not sure this is even worth getting tested.   Jul 28 2020, 08:55 PM
bkrantz   To warm up, I started with the ignition harness. ...   Jul 28 2020, 08:57 PM
bkrantz   After a bit of work, it looks pretty good.   Jul 28 2020, 08:58 PM
bkrantz   Anyone know where to source these hard plastic con...   Jul 28 2020, 08:59 PM
bkrantz   The one problem to fix is a splice and non-stock c...   Jul 28 2020, 09:01 PM
bkrantz   Since the distance is short, I want to replace the...   Jul 28 2020, 09:02 PM
bkrantz   So that got me motivated to organize all my electr...   Jul 28 2020, 09:03 PM
76-914   So that got me motivated to organize all my elect...   Jul 30 2020, 08:21 PM
bkrantz   My new crimp tool with multiple crimp dies.   Jul 28 2020, 09:04 PM
bkrantz   My trusty old tool box filled with connectors and ...   Jul 28 2020, 09:05 PM
bkrantz   And my supply of wire, looking a bit low. And no ...   Jul 28 2020, 09:07 PM
bkrantz   Before ordering more wire and parts, I need anothe...   Jul 28 2020, 09:09 PM
bkrantz   Laid out for tomorrow.   Jul 28 2020, 09:11 PM
djway   Wolfsburg West has the dual male insulated connect...   Jul 28 2020, 11:29 PM
bkrantz   Wolfsburg West has the dual male insulated connec...   Jul 29 2020, 09:10 PM
bkrantz   More careful diagnosis of the main harness today. ...   Jul 29 2020, 09:12 PM
bkrantz   Sometimes crimped.   Jul 29 2020, 09:13 PM
bkrantz   Other places are missing connectors on the ends of...   Jul 29 2020, 09:13 PM
bkrantz   And the mouse damage continues.   Jul 29 2020, 09:14 PM
raynekat   Isn't electrical harness stuff fun? Hate it, b...   Jul 29 2020, 09:41 PM
bkrantz   Might be fun (or maybe what my PhD advisor called ...   Jul 30 2020, 07:49 PM
bkrantz   I stopped by the body shop today, and caught them ...   Jul 30 2020, 07:51 PM
djway   I order connectors at Digi Key in bulk and 100ft r...   Jul 31 2020, 12:06 AM
bkrantz   Thanks, guys. I learned about soldering from my l...   Jul 31 2020, 08:13 PM
bkrantz   More harness work today, still mostly in cleaning ...   Jul 31 2020, 08:16 PM
bkrantz   Of course, as I clean wires I find more issues, ra...   Jul 31 2020, 08:17 PM
djway   Of course, as I clean wires I find more issues, r...   Aug 1 2020, 12:25 AM
bkrantz   While sorting through the interior parts I redisco...   Jul 31 2020, 08:26 PM
Cairo94507   That is the chassis number (not to be confused wit...   Aug 1 2020, 03:26 AM
bkrantz   That is the chassis number (not to be confused wi...   Aug 1 2020, 07:55 PM
bkrantz   My left replacement strut arrived from 914 Werke. ...   Aug 1 2020, 08:00 PM
bkrantz   I finished my main harness survey today, and found...   Aug 1 2020, 08:03 PM
djway   I finished my main harness survey today, and foun...   Aug 1 2020, 11:33 PM
bkrantz   And, hiding under some old tape, evidence of high ...   Aug 1 2020, 08:05 PM
bkrantz   Altogether, I found 30 problems to repair (so far)...   Aug 1 2020, 08:06 PM
bkrantz   Trying to gather all the parts I will have powder-...   Aug 2 2020, 08:38 PM
bkrantz   Complete with moldy air filter.   Aug 2 2020, 08:39 PM
bkrantz   While in a red mood, I pulled out the transaxle. ...   Aug 2 2020, 08:40 PM
bkrantz   After muscling the trans into and around the parts...   Aug 3 2020, 07:35 PM
bkrantz   One more item in the Red Collection: the intake ru...   Aug 3 2020, 07:37 PM
bkrantz   At least the injectors are all green. Time to sen...   Aug 3 2020, 07:38 PM
bkrantz   I also took apart the intake plenum and throttle b...   Aug 3 2020, 07:40 PM
bkrantz   Inside the plenum: oily sludge!   Aug 3 2020, 07:40 PM
djway   Regarding all the Red, what can I say it was the 8...   Aug 3 2020, 10:57 PM
bkrantz   Still sorting through boxes from the disassembly l...   Aug 4 2020, 07:59 PM
bkrantz   Here's the fuel pump, with some red--but not t...   Aug 4 2020, 08:03 PM
bkrantz   Another project: the relay board. Ugly.   Aug 4 2020, 08:06 PM
bkrantz   The underside is even uglier, and the dielectric m...   Aug 4 2020, 08:08 PM
bkrantz   A little persuasion, and the stuff comes off. I n...   Aug 4 2020, 08:10 PM
bkrantz   Next up: the brain box. Another great OP idea, pa...   Aug 4 2020, 08:13 PM
bkrantz   At least the inside looks clean.   Aug 4 2020, 08:14 PM
bkrantz   I made a first pass at cleaning the brain today, w...   Aug 5 2020, 08:03 PM
bkrantz   That took off the black, but left the red (overspr...   Aug 5 2020, 08:04 PM
bkrantz   A follow-up with progress on the brain box, after ...   Aug 6 2020, 07:50 PM
bkrantz   The metal finish is still ugly. Not sure what to ...   Aug 6 2020, 07:52 PM
bkrantz   The relay board looks better. Soaking overnight i...   Aug 6 2020, 07:55 PM
bkrantz   The top side also looks better.   Aug 6 2020, 07:55 PM
bkrantz   Meanwhile, I have continued working on the main ha...   Aug 6 2020, 07:58 PM
bkrantz   Posting this photo here so I can link it to the VI...   Aug 6 2020, 08:09 PM
bkrantz   And the next page.   Aug 6 2020, 08:10 PM
bkrantz   Oh fudge! While sorting through more boxes of...   Aug 7 2020, 08:41 PM
bkrantz   I wanted to get this to the powder coating shop to...   Aug 7 2020, 08:43 PM
bkrantz   Back at work on the wiring harness, and I complete...   Aug 8 2020, 08:54 PM
bkrantz   I could not resist starting to fix things. Since ...   Aug 8 2020, 08:57 PM
bkrantz   I then used a length of welding wire to snake the ...   Aug 8 2020, 08:58 PM
bkrantz   Here are the pump wires, now reaching into the pas...   Aug 8 2020, 09:00 PM
bkrantz   I also worked on the tail light lenses. I was car...   Aug 8 2020, 09:01 PM
bkrantz   I found some industrial acrylic welding fluid, tha...   Aug 8 2020, 09:03 PM
bkrantz   I also found cracks around one of the stud bases. ...   Aug 8 2020, 09:05 PM
bkrantz   The corner looks rough from "below".   Aug 8 2020, 09:05 PM
bkrantz   But pretty good in normal orientation.   Aug 8 2020, 09:06 PM
bkrantz   When I checked the right lens, I was surprised to ...   Aug 8 2020, 09:08 PM
bkrantz   But relatively easy to repair with the weld compou...   Aug 8 2020, 09:09 PM
djway   But relatively easy to repair with the weld compo...   Aug 9 2020, 10:55 PM
bbrock   But relatively easy to repair with the weld comp...   Aug 10 2020, 07:49 AM
bkrantz   And I also checked the fog lamps. One looks prett...   Aug 8 2020, 09:11 PM
bkrantz   But the other lamp has major issues, with corrosio...   Aug 8 2020, 09:13 PM
bkrantz   Plus rust inside the reflector. This one needs a ...   Aug 8 2020, 09:13 PM
bkrantz   I took a look at the pedal cluster today. Overall...   Aug 9 2020, 07:41 PM
bkrantz   But the throttle lever has some interesting PO bra...   Aug 9 2020, 07:42 PM
bkrantz   Have you guys ever replaced the foam gasket around...   Aug 10 2020, 09:10 PM
bbrock   Have you guys ever replaced the foam gasket aroun...   Aug 10 2020, 10:31 PM
raynekat   Have you guys ever replaced the foam gasket aroun...   Aug 11 2020, 12:33 AM
bkrantz   Thanks, Brent. You are much more helpful than Dou...   Aug 12 2020, 08:17 PM
bkrantz   Cleaning wires is getting tedious. I spent about ...   Aug 12 2020, 08:20 PM
bkrantz   I carried on today, and finished cleaning the wiri...   Aug 13 2020, 08:01 PM
bkrantz   The wires look pretty good now, and seem intact--j...   Aug 13 2020, 08:03 PM
bbrock   Looking good. Try hitting them with some 303 Prot...   Aug 13 2020, 10:07 PM
bkrantz   Looking good. Try hitting them with some 303 Pro...   Aug 14 2020, 08:28 PM
bkrantz   I got into wire repair mode today. Here is the se...   Aug 14 2020, 08:31 PM
bkrantz   First up: 2 leads to the ignition switch plug. On...   Aug 14 2020, 08:34 PM
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