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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   Then the tail light branch.   Dec 16 2020, 08:35 PM
ndfrigi   Congratulations! not just installing it but th...   Dec 16 2020, 08:36 PM
bkrantz   All of the left branch through.   Dec 16 2020, 08:36 PM
bkrantz   And the right branch with the battery leads throug...   Dec 16 2020, 08:38 PM
bkrantz   Now I could feed the upper end of the snorkel thro...   Dec 16 2020, 08:42 PM
bkrantz   Turns out I found lots of sharp edges with my fing...   Dec 16 2020, 08:44 PM
djway   Turns out I found lots of sharp edges with my fin...   Dec 16 2020, 11:26 PM
bkrantz   Turns out I found lots of sharp edges with my fi...   Dec 17 2020, 08:01 PM
bkrantz   That's success for the rear harness through th...   Dec 16 2020, 08:46 PM
raynekat   Nice job there Bob. That was a painful, cursing ta...   Dec 17 2020, 03:09 AM
Kansas 914   Stellar work Bob!   Dec 17 2020, 07:43 AM
bkrantz   Stellar work Bob! Thanks, Mike. I need to ...   Dec 17 2020, 08:01 PM
Kansas 914   Thanks, Mike. I need to invent a reason to see s...   Dec 18 2020, 08:03 AM
bkrantz   [quote name='bkrantz' post='2875881' date='Dec 17...   Dec 18 2020, 07:55 PM
bkrantz   Nice job there Bob. That was a painful, cursing t...   Dec 17 2020, 08:00 PM
BillC   Extremely nice. Well done! Thanks for all th...   Dec 17 2020, 09:10 AM
bkrantz   Just a couple of trivial things today, including t...   Dec 17 2020, 08:03 PM
bkrantz   And cleaning the grounding stud under the dash.   Dec 17 2020, 08:04 PM
bkrantz   Back to work today, on the front end of the wiring...   Dec 18 2020, 07:56 PM
bkrantz   All that has to go through the small hole (big hol...   Dec 18 2020, 07:58 PM
bkrantz   This is definitely the time for "biggest goes...   Dec 18 2020, 08:09 PM
bkrantz   Here we go.   Dec 18 2020, 08:10 PM
bkrantz   Next, the far ends of the front light leads. The ...   Dec 18 2020, 08:10 PM
bkrantz   More leads started through the hole. Note the big...   Dec 18 2020, 08:12 PM
bkrantz   Progress, from the inside.   Dec 18 2020, 08:15 PM
bkrantz   Everything is now at least started.   Dec 18 2020, 08:16 PM
bkrantz   Squeezed the fuel tank bulkhead grommet through.   Dec 18 2020, 08:17 PM
bkrantz   I attached the ground leads to the stud while stil...   Dec 18 2020, 08:18 PM
bkrantz   And then got the big grommet seated. It still sho...   Dec 18 2020, 08:19 PM
bkrantz   Another personal milestone: this is the first time...   Dec 18 2020, 08:21 PM
bkrantz   Fuse-relay panel in place.   Dec 18 2020, 08:22 PM
bkrantz   All the wires that will go in or under the dash.   Dec 18 2020, 08:23 PM
bkrantz   Now for the wires in the front.   Dec 18 2020, 08:25 PM
bkrantz   Starting the leads through the fuel tank bulkhead.   Dec 18 2020, 08:26 PM
bkrantz   Pretty full--all the leads started.   Dec 18 2020, 08:27 PM
bkrantz   From the tank side.   Dec 18 2020, 08:28 PM
bkrantz   Grommet seated (and more blood shed).   Dec 18 2020, 08:29 PM
bkrantz   Quick layout of the light leads.   Dec 18 2020, 08:30 PM
bkrantz   And the leads for under the cowl and fuel tank.   Dec 18 2020, 08:30 PM
bkrantz   First step today: removing paint from more groundi...   Dec 19 2020, 07:52 PM
bkrantz   Then the stud by the battery. Before...   Dec 19 2020, 07:53 PM
bkrantz   After.   Dec 19 2020, 07:54 PM
bkrantz   And the stud for the transaxle grounding strap.   Dec 19 2020, 07:55 PM
bkrantz   OK, ready to start on the harness routing in the e...   Dec 19 2020, 07:57 PM
bkrantz   Time for some 3M rubber tape.   Dec 19 2020, 07:58 PM
bkrantz   Better.   Dec 19 2020, 08:00 PM
bkrantz   Right harness branch, leading to the battery.   Dec 19 2020, 08:03 PM
bkrantz   Left branch, first to the relay board and the blow...   Dec 19 2020, 08:07 PM
bkrantz   And then the lead to the trunk light.   Dec 19 2020, 08:08 PM
bkrantz   Leaving the leads to the tail lights.   Dec 19 2020, 08:09 PM
bkrantz   First, getting the grommet on the left side in pla...   Dec 19 2020, 08:10 PM
bkrantz   And then arranging the harness to the lights.   Dec 19 2020, 08:11 PM
bkrantz   Including the license plate lights.   Dec 19 2020, 08:11 PM
bkrantz   I also went back to the passenger compartment, to ...   Dec 19 2020, 08:18 PM
bkrantz   Here's my planned routing (but inside the cros...   Dec 19 2020, 08:20 PM
bkrantz   To fish the lead, I used a length of welding wire,...   Dec 19 2020, 08:21 PM
bkrantz   The end popped out the switch hole on the first tr...   Dec 19 2020, 08:22 PM
bkrantz   That made it easy to pull the switch lead.   Dec 19 2020, 08:23 PM
djway   This whole thing has left me feeling WIRED :blink...   Dec 19 2020, 09:33 PM
bkrantz   This whole thing has left me feeling WIRED :blin...   Dec 20 2020, 08:43 PM
bkrantz   More work on the front harness today, getting thin...   Dec 20 2020, 08:46 PM
bkrantz   Right side in place, except for the turn signal le...   Dec 20 2020, 08:47 PM
bkrantz   Fog light and horn leads out the front.   Dec 20 2020, 08:48 PM
bkrantz   Getting close to final harness location, with new ...   Dec 21 2020, 08:14 PM
bkrantz   Left side under the cowl.   Dec 21 2020, 08:14 PM
bkrantz   Left side of trunk.   Dec 21 2020, 08:15 PM
bkrantz   Left side of engine compartment.   Dec 21 2020, 08:16 PM
bkrantz   Finishing up tying down the harness, with the doub...   Dec 22 2020, 07:58 PM
bkrantz   And under the driver side of the dash.   Dec 22 2020, 07:58 PM
bkrantz   Lining for front brace openings to protect wires.   Dec 23 2020, 08:58 PM
bkrantz   Brake line day! Matching the new SS lines fro...   Dec 23 2020, 08:59 PM
bkrantz   Cleaning threads.   Dec 23 2020, 09:01 PM
bkrantz   Rebuilt pressure regulator valve, also from PMB, a...   Dec 23 2020, 09:04 PM
bkrantz   Right rear line.   Dec 23 2020, 09:05 PM
bkrantz   Left rear line.   Dec 23 2020, 09:05 PM
bkrantz   I need the T-junction for the top connection.   Dec 23 2020, 09:06 PM
bkrantz   Short connection from the front of the tunnel line...   Dec 23 2020, 09:07 PM
bkrantz   Front right line.   Dec 23 2020, 09:08 PM
bkrantz   Front left line.   Dec 23 2020, 09:09 PM
bkrantz   Another task: the frunk release. New cable housin...   Dec 23 2020, 09:12 PM
bkrantz   Along the inner fender--easy enough to follow the ...   Dec 23 2020, 09:13 PM
bkrantz   I used this hole in the horizontal brace, but deci...   Dec 23 2020, 09:18 PM
bkrantz   And into the latch.   Dec 23 2020, 09:19 PM
bkrantz   Progress on the latest list.   Dec 23 2020, 09:23 PM
Kansas 914   Great documentation on the brake lines. I need to ...   Dec 24 2020, 08:01 AM
iankarr   Your car...and build...looks amazing. Congrats...   Dec 24 2020, 12:07 PM
bkrantz   Your car...and build...looks amazing. Congrats...   Dec 24 2020, 09:17 PM
bkrantz   More wiring details: grommets and leads for the re...   Dec 24 2020, 09:19 PM
bkrantz   I also finished up the frunk release. Here are th...   Dec 24 2020, 09:24 PM
bkrantz   Here's the pull wire, before trimming.   Dec 24 2020, 09:26 PM
bkrantz   And the latch mounted in place.   Dec 24 2020, 09:27 PM
bkrantz   With the release handle ready for action.   Dec 24 2020, 09:28 PM
bkrantz   And then I started on the gear shift lever, in pre...   Dec 24 2020, 09:34 PM
bkrantz   That's 50 year old vintage grease.   Dec 24 2020, 09:34 PM
bkrantz   After initial cleaning. I tried to use my parts w...   Dec 24 2020, 09:37 PM
bkrantz   I need to order a circlip before I can rebuild the...   Dec 26 2020, 08:18 PM
bkrantz   Pedals in place, with shiny new hardware.   Dec 26 2020, 08:18 PM
bkrantz   I then tackled preparing the new master cylinder. ...   Dec 26 2020, 08:20 PM
bkrantz   Step 1, transfer the inner washers for the supply ...   Dec 26 2020, 08:22 PM
bkrantz   And then re-install the new rubber grommets (old o...   Dec 26 2020, 08:23 PM
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