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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   Thanks, Blown. I enjoy stopping to take phots, an...   Sep 13 2020, 06:53 PM
bkrantz   I inspected the shift rods today. The both look f...   Sep 13 2020, 06:55 PM
bkrantz   The linkage, though, looks a bit (or more) loose. ...   Sep 13 2020, 06:56 PM
bkrantz   It took about 30 seconds to remove the pivot shaft...   Sep 13 2020, 06:58 PM
bkrantz   Speaking of the press, I installed the rear wheel ...   Sep 13 2020, 07:01 PM
bkrantz   I like using a press with a pressure gauge, so tha...   Sep 13 2020, 07:02 PM
bkrantz   Bearing in place.   Sep 13 2020, 07:04 PM
bkrantz   And retainer with shiny new hardware. Mmmm.   Sep 13 2020, 07:05 PM
bkrantz   Good reason to tap into my newly created home hard...   Sep 13 2020, 07:06 PM
bkrantz   Lots of shiny stuff!   Sep 13 2020, 07:06 PM
bkrantz   Then time to press in the wheel flanges. Note: in...   Sep 13 2020, 07:07 PM
bkrantz   Flange in place.   Sep 13 2020, 07:09 PM
bkrantz   Trailing arms done!   Sep 13 2020, 07:10 PM
Kansas 914   Terrific work Bob. I have a bead blaster you are ...   Sep 13 2020, 08:01 PM
djway   Tools are Swell!   Sep 13 2020, 11:37 PM
bkrantz   Tools are Swell! Agreed. Here's my lat...   Sep 14 2020, 07:30 PM
bkrantz   Another batch of parts after Evaporators-rust trea...   Sep 14 2020, 07:33 PM
bkrantz   One of the half-shaft flanges has some upturned ed...   Sep 14 2020, 07:36 PM
bkrantz   Took care of those with a flat file.   Sep 14 2020, 07:37 PM
bkrantz   To test the flange flatness, as was discussed in a...   Sep 14 2020, 07:40 PM
brant   I just went through the whole thread amazing real...   Sep 15 2020, 03:27 PM
bkrantz   I just went through the whole thread amazing rea...   Sep 15 2020, 07:39 PM
bkrantz   I took a closer look at one of the CV joints, with...   Sep 15 2020, 07:41 PM
bkrantz   And the cage.   Sep 15 2020, 07:41 PM
bkrantz   And the inner flange. I suspect these show extrem...   Sep 15 2020, 07:43 PM
bkrantz   With all the parts and supplies in hand, I started...   Sep 15 2020, 07:45 PM
bkrantz   I never removed the inner pivot bearing, just clea...   Sep 15 2020, 07:45 PM
bkrantz   I made my own grease injector, to fill below the l...   Sep 15 2020, 07:46 PM
bkrantz   Then I greased up the rack, and slid that into pla...   Sep 15 2020, 07:48 PM
bkrantz   Here's the pivot, with the upper bearing in pl...   Sep 15 2020, 07:50 PM
bkrantz   Then packed the interior with more grease.   Sep 15 2020, 07:51 PM
bkrantz   With the rack centered, I installed the pivot. Th...   Sep 15 2020, 07:53 PM
bkrantz   Next, the shims I removed and the lock ring.   Sep 15 2020, 07:54 PM
bkrantz   With everything installed, I checked for end play:...   Sep 15 2020, 07:56 PM
Kansas 914   With everything installed, I checked for end play...   Sep 15 2020, 07:59 PM
bkrantz   Then the pivot shaft seal, which I found based on ...   Sep 15 2020, 07:57 PM
bkrantz   Seal in place.   Sep 15 2020, 07:57 PM
bkrantz   Then center the rack...   Sep 15 2020, 07:58 PM
bkrantz   ...and install the yoke, oriented vertically.   Sep 15 2020, 07:59 PM
bkrantz   With the rack flipped over, I installed the pressu...   Sep 15 2020, 07:59 PM
bkrantz   The end of the block sits just below the housing f...   Sep 15 2020, 08:01 PM
bkrantz   Next, I measured the recess in the cover plate, 1....   Sep 15 2020, 08:02 PM
bkrantz   Then I measured the thickness of the original shim...   Sep 15 2020, 08:04 PM
bkrantz   Here's the math. The total gap, including the...   Sep 15 2020, 08:07 PM
bkrantz   Here's the pressure spring, and the cover plat...   Sep 15 2020, 08:08 PM
bkrantz   Finally, here is the rack all done.   Sep 15 2020, 08:08 PM
autopro   This is awesome, I will be doing this to my rack s...   Sep 16 2020, 11:59 AM
bkrantz   Steering rack, part 2. I started with the eye-bol...   Sep 16 2020, 07:40 PM
bkrantz   No instructions, so I made up my own. Here's ...   Sep 16 2020, 07:42 PM
bkrantz   After the first attempt to press in the bushing. ...   Sep 16 2020, 07:44 PM
bkrantz   Another squeeze, just to the limit of pinching.   Sep 16 2020, 07:46 PM
bkrantz   With the pressure released, the bushing rebounded ...   Sep 16 2020, 07:48 PM
bkrantz   I then pressed into a 27mm socket, matching the ou...   Sep 16 2020, 07:49 PM
bkrantz   That was enough to get just a bit of the bushing e...   Sep 16 2020, 07:50 PM
bkrantz   I then used my blunt ex-screw driver pry tool to e...   Sep 16 2020, 07:51 PM
bkrantz   Done.   Sep 16 2020, 07:51 PM
bkrantz   Then I pressed in the metal center bushing. Again...   Sep 16 2020, 07:52 PM
bkrantz   And then a smaller socket to press against the rub...   Sep 16 2020, 07:53 PM
bkrantz   Centered.   Sep 16 2020, 07:54 PM
bkrantz   Ready for the final assembly. The specs come from...   Sep 16 2020, 07:57 PM
bkrantz   I then put on the bellows (small end to the inside...   Sep 16 2020, 07:58 PM
bkrantz   And the eye bolts with the stop plates.   Sep 16 2020, 07:59 PM
bkrantz   To get the rack to sit properly horizontal, I made...   Sep 16 2020, 08:00 PM
bkrantz   With a little adjustment, the rack now sits horizo...   Sep 16 2020, 08:01 PM
bkrantz   To measure the angles of the eye bolts, I grabbed ...   Sep 16 2020, 08:03 PM
bkrantz   Here's a top view, with the bolts propped up o...   Sep 16 2020, 08:04 PM
bkrantz   Lucky 2x4 thickness! The angle is right on 9 ...   Sep 16 2020, 08:05 PM
bkrantz   Next is to measure the lateral dimension, with the...   Sep 16 2020, 08:09 PM
bkrantz   I set both sides. Interesting that the left side ...   Sep 16 2020, 08:11 PM
bkrantz   I snugged up the lock rings, but will check dimens...   Sep 16 2020, 08:12 PM
bkrantz   Final bits today for the steering rack. I did dou...   Sep 17 2020, 06:45 PM
bkrantz   Here's all the parts gathered for installing t...   Sep 17 2020, 06:47 PM
bkrantz   The coupler first mounts to the lower shaft.   Sep 17 2020, 06:48 PM
bkrantz   After torquing to proper spec, the ends of the loc...   Sep 17 2020, 06:49 PM
bkrantz   And then the coupler bolts onto the rack input yok...   Sep 17 2020, 06:51 PM
bkrantz   Lock these bolts in place, too.   Sep 17 2020, 06:51 PM
bkrantz   Then comes the plastic cover and the lower shaft b...   Sep 17 2020, 06:53 PM
bkrantz   Just some minor progress today. I took another bat...   Sep 18 2020, 07:40 PM
bkrantz   Also from the bucket, the transaxle mount pieces.   Sep 18 2020, 07:42 PM
bkrantz   And starting on the parking brake lever. A bit ug...   Sep 18 2020, 07:44 PM
bkrantz   A bit of garage cooking, to warm up the plastic gr...   Sep 19 2020, 07:18 PM
bkrantz   Grip removed, and a bit more cleanup.   Sep 19 2020, 07:19 PM
bkrantz   Primed and painted.   Sep 19 2020, 07:24 PM
raynekat   Much better looking there Bob. Nice   Sep 19 2020, 07:29 PM
bkrantz   Now for the big job of the day: installing the rub...   Sep 19 2020, 07:31 PM
bkrantz   Here's my process. 1. Press the bushing into ...   Sep 19 2020, 07:34 PM
bkrantz   2. Bushing pressed in.   Sep 19 2020, 07:36 PM
bkrantz   Here's the 914 Rubber inner guide, to ease the...   Sep 19 2020, 07:37 PM
bkrantz   The guide in place.   Sep 19 2020, 07:38 PM
bkrantz   3. Starting to press the bushing on, over the guid...   Sep 19 2020, 07:40 PM
bkrantz   Pressed all the way on. With the pressure release...   Sep 19 2020, 07:43 PM
bkrantz   So I reversed the guide and pressed again against ...   Sep 19 2020, 07:46 PM
bkrantz   4. Once installed, the bushing and housing must be...   Sep 19 2020, 07:48 PM
bkrantz   Then, check the angle of the housing. It should b...   Sep 19 2020, 07:50 PM
bkrantz   A bit of twisting.   Sep 19 2020, 07:51 PM
bkrantz   Now 14 degrees.   Sep 19 2020, 07:51 PM
bkrantz   5. Install the rubber bushings into the front A-a...   Sep 19 2020, 07:54 PM
bkrantz   Like the rears, lots of soap, and press the rubber...   Sep 19 2020, 07:56 PM
bkrantz   Ready for the A-arms.   Sep 19 2020, 07:56 PM
bkrantz   6. Pressed into place.   Sep 19 2020, 07:59 PM
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