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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   Success! Too bad I can't upload a video, ...   Aug 27 2020, 07:28 PM
bbrock   Success! Too bad I can't upload a video,...   Aug 27 2020, 07:41 PM
bkrantz   I also made a trip out, first to the powder coat s...   Aug 27 2020, 07:31 PM
bkrantz   And then a stop at the body shop. Unfortunately, ...   Aug 27 2020, 07:37 PM
bkrantz   A bit more suspension work today. I cleaned up th...   Aug 28 2020, 08:01 PM
bkrantz   I found a bit of pitting on one end of each axle--...   Aug 28 2020, 08:03 PM
bkrantz   Next up, the steering rack.   Aug 28 2020, 08:05 PM
bkrantz   I felt quite a bit of play in the rubber coupling.   Aug 28 2020, 08:08 PM
bkrantz   Here's the problem: the holes in the coupler a...   Aug 28 2020, 08:10 PM
bkrantz   I was able to loosen the lock rings/bellow support...   Aug 28 2020, 08:15 PM
bkrantz   The rack itself seems solid, with just a tiny perc...   Aug 28 2020, 08:17 PM
bkrantz   Today, I tackled the rack disassembly. After a vi...   Aug 30 2020, 07:23 PM
bkrantz   First, I removed the the compression cover and par...   Aug 30 2020, 07:24 PM
bkrantz   Here's the pinion shaft seal in place.   Aug 30 2020, 07:26 PM
bkrantz   I tried to remove this intact, but no dice.   Aug 30 2020, 07:27 PM
bkrantz   Then I found the retaining ring for the upper pini...   Aug 30 2020, 07:28 PM
bkrantz   No problem with snap ring pliers.   Aug 30 2020, 07:28 PM
bkrantz   I then pried out the pinion shaft. Although even ...   Aug 30 2020, 07:30 PM
bkrantz   The pinion shaft came out with good news: still lo...   Aug 30 2020, 07:31 PM
bkrantz   With the pinion removed, the rack shaft slid out. ...   Aug 30 2020, 07:33 PM
bkrantz   I also pressed the old bushings out of the eye bol...   Aug 30 2020, 07:40 PM
bkrantz   Easy-peasy with the press. Ready for the replacem...   Aug 30 2020, 07:41 PM
bkrantz   I also took on the mangled retaining ring/bellows ...   Aug 30 2020, 07:43 PM
bkrantz   Anyway, 5 minutes later.   Aug 30 2020, 07:43 PM
bkrantz   The last thing I did was make some paper templates...   Aug 30 2020, 07:45 PM
bkrantz   Besides all the garage work, and sending things ou...   Aug 31 2020, 06:35 PM
bkrantz   I tried mounting some bushings today, starting wit...   Aug 31 2020, 06:38 PM
bkrantz   Then a bit of garage cooking to soften up the bush...   Aug 31 2020, 06:40 PM
bkrantz   Unfortunately, my first attempt failed. I ripped ...   Aug 31 2020, 06:43 PM
bkrantz   Waiting for more stuff before playing with bushing...   Sep 1 2020, 07:35 PM
bkrantz   And some PO already installed bronze bushings.   Sep 1 2020, 07:36 PM
bkrantz   I pondered using the pedals as they are, but..nah,...   Sep 1 2020, 07:39 PM
bkrantz   Back in town, and a bit of time to kill--and new t...   Sep 4 2020, 08:08 PM
bkrantz   Very quick and easy to cut out any distortion that...   Sep 4 2020, 08:09 PM
bkrantz   Fixed (enough).   Sep 4 2020, 08:10 PM
bkrantz   Then I used my new 16 x 1.5 tap, to dress the thre...   Sep 4 2020, 08:11 PM
bkrantz   Again, very easy with only very minor torque neces...   Sep 4 2020, 08:12 PM
bkrantz   Mission accomplished. The eye bolt now threads sm...   Sep 4 2020, 08:12 PM
bkrantz   I started working on the trailing arms today, with...   Sep 5 2020, 07:37 PM
bkrantz   I pushed a bushing onto one end of the pivot.   Sep 5 2020, 07:39 PM
bkrantz   And then pushed both into the trailing arm.   Sep 5 2020, 07:40 PM
bkrantz   That left the other end needing a bushing.   Sep 5 2020, 07:41 PM
bkrantz   So, add some liquid soap...   Sep 5 2020, 07:41 PM
bkrantz   ...and shove the bushing in by hand as far as poss...   Sep 5 2020, 07:42 PM
bkrantz   ...and finish with the press.   Sep 5 2020, 07:43 PM
bkrantz   All done.   Sep 5 2020, 07:44 PM
bbrock   All done. Thanks for posting the trailing arm p...   Sep 6 2020, 08:30 PM
bkrantz   I also took apart the tie rods. More to do on the...   Sep 5 2020, 07:45 PM
djway   Some things in life are just more pressing than ot...   Sep 5 2020, 10:57 PM
bkrantz   Some things in life are just more pressing than o...   Sep 6 2020, 07:31 PM
bkrantz   Time for some 914 wood working today. Some audiop...   Sep 6 2020, 07:35 PM
bkrantz   I traced the openings individually, and got out my...   Sep 6 2020, 07:37 PM
bkrantz   Then some sanding to get a precise fit.   Sep 6 2020, 07:38 PM
bkrantz   Glued in place. I will test the bond tomorrow. A...   Sep 6 2020, 07:40 PM
bkrantz   Brent, it really did not take much force to instal...   Sep 7 2020, 06:56 PM
bkrantz   Just a bit of token work today. I sanded the cons...   Sep 7 2020, 06:57 PM
jaredmcginness   Great and quick work. I love the fresh coats on ev...   Sep 7 2020, 07:00 PM
bkrantz   Great and quick work. I love the fresh coats on e...   Sep 8 2020, 07:53 PM
bkrantz   Still in a holding pattern, and so taking a chance...   Sep 9 2020, 07:00 PM
bkrantz   And I have just half of the sun visor hardware.   Sep 9 2020, 07:01 PM
bkrantz   AndI decided to test the epoxy potting compound I ...   Sep 9 2020, 07:03 PM
bbrock   AndI decided to test the epoxy potting compound I...   Sep 10 2020, 12:30 PM
bkrantz   This is supposed to be flexible so I hope resistin...   Sep 9 2020, 07:03 PM
bkrantz   Seems simple enough, with a 50-50 mix and long cur...   Sep 9 2020, 07:04 PM
bkrantz   To test the adhesion to the relay board plastic, I...   Sep 9 2020, 07:07 PM
Kansas 914   To test the adhesion to the relay board plastic, ...   Sep 9 2020, 07:15 PM
bkrantz   Me too! It might take 48 hours to fully cure.   Sep 9 2020, 07:54 PM
ndfrigi   Saw few members used it and it is on my amazon car...   Sep 10 2020, 01:15 PM
bkrantz   Visited the body shop today, and progress has begu...   Sep 10 2020, 07:55 PM
bkrantz   The body is again outside, but they should be sand...   Sep 10 2020, 07:56 PM
bkrantz   Chemistry lab today. Time to play with these and ...   Sep 11 2020, 08:11 PM
bkrantz   First, check on the flexible epoxy from 2 days ago...   Sep 11 2020, 08:12 PM
bkrantz   And also very flexible, able to fold in half and s...   Sep 11 2020, 08:13 PM
bkrantz   I also checked the test spots I poured on the rela...   Sep 11 2020, 08:15 PM
bkrantz   Next, I tried some paint stripper on the blacked o...   Sep 11 2020, 08:17 PM
bkrantz   The stripper works well enough, but reveals that l...   Sep 11 2020, 08:19 PM
bkrantz   Then I started a test for materials to protect unp...   Sep 11 2020, 08:21 PM
bkrantz   Finally, I gather some miscellaneous small parts w...   Sep 11 2020, 08:23 PM
bkrantz   And the rear wheel bearing retainer plates.   Sep 11 2020, 08:25 PM
bkrantz   And the rear wheel flanges.   Sep 11 2020, 08:26 PM
bkrantz   All these and more went into the Evaporators-rust ...   Sep 11 2020, 08:27 PM
bkrantz   Coincidently, I have been reading a fun book about...   Sep 11 2020, 08:31 PM
bkrantz   Chemistry lab follow up. First the epoxy seems a ...   Sep 12 2020, 07:45 PM
bkrantz   Next, the corrosion inhibitors. These were both v...   Sep 12 2020, 07:46 PM
bkrantz   I patted them mostly dry with a paper towel--check...   Sep 12 2020, 07:48 PM
bkrantz   Now for the Evaporators-rust. Pulling out the bas...   Sep 12 2020, 07:49 PM
bkrantz   The small fasteners are almost rust free.   Sep 12 2020, 07:51 PM
bkrantz   The bearing retainers look almost new.   Sep 12 2020, 07:51 PM
bkrantz   Flanges have no rust.   Sep 12 2020, 07:52 PM
bkrantz   Neither do the trailing arm alignment spacers.   Sep 12 2020, 07:53 PM
bkrantz   Nice looking trailing arm shock bolts.   Sep 12 2020, 07:54 PM
bkrantz   Most improved: the front torsion bar adjusters. T...   Sep 12 2020, 07:55 PM
bkrantz   OK, now for some real work. Time to disassemble t...   Sep 12 2020, 07:56 PM
bkrantz   Creative washer on one flange bolt. Copper?   Sep 12 2020, 07:58 PM
bkrantz   Interesting gouge inside one flange.   Sep 12 2020, 07:58 PM
bkrantz   Now onto the standard procedure. Remove the cir-c...   Sep 12 2020, 08:00 PM
bkrantz   Pop off the CV joint and boot.   Sep 12 2020, 08:01 PM
bkrantz   Repeat on the other end, and then break down the C...   Sep 12 2020, 08:02 PM
bkrantz   And after some quality time in the parts washer.   Sep 12 2020, 08:03 PM
Blown59   Looking through your thread and seeing all that yo...   Sep 12 2020, 08:23 PM
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