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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   And then attach the new supply plastic tubing to t...   Dec 26 2020, 08:25 PM
bkrantz   I first tried warning the end of the plastic tubin...   Dec 26 2020, 08:26 PM
bkrantz   But, the tubing got too warm and buckled when I tr...   Dec 26 2020, 08:27 PM
bkrantz   So for the second try, I warmed the metal barbs an...   Dec 26 2020, 08:28 PM
bkrantz   I lubed the grommets with brake fluid.   Dec 26 2020, 08:29 PM
bkrantz   And then eased (and pushed) the flanged ends into ...   Dec 26 2020, 08:32 PM
bkrantz   MC mounted, with the supply lines up through the f...   Dec 26 2020, 08:35 PM
bkrantz   I think I need new angled grommets for the supply ...   Dec 26 2020, 08:36 PM
bkrantz   Also, a new boot for the warning switch. I decide...   Dec 26 2020, 08:38 PM
bkrantz   Before mounting the banjo fitting for the front li...   Dec 26 2020, 08:41 PM
bkrantz   Meanwhile, I put my visiting son to work again, fi...   Dec 26 2020, 08:48 PM
bkrantz   The obvious thing is to pour this into the inverte...   Dec 26 2020, 08:53 PM
bkrantz   Here's the wax, forced into the holes from the...   Dec 26 2020, 08:54 PM
bkrantz   And from below (sorry for the fuzzy photo).   Dec 26 2020, 08:55 PM
bkrantz   Finally, we leveled the relay board.   Dec 26 2020, 08:55 PM
bkrantz   Then mixed the potting compound and poured in abou...   Dec 26 2020, 08:56 PM
bkrantz   For about 15 minutes, we popped some air bubbles. ...   Dec 26 2020, 08:58 PM
bkrantz   Now just wait 24 to 48 hours for full cure.   Dec 26 2020, 08:59 PM
bkrantz   Finishing up the relay board. The potting compoun...   Dec 28 2020, 08:05 PM
bkrantz   Compound leaked through the side notches, and onto...   Dec 28 2020, 08:06 PM
bkrantz   And the compound found more leak points, including...   Dec 28 2020, 08:07 PM
bkrantz   And the 3-pin socket, and one tab for the fuses.   Dec 28 2020, 08:08 PM
bkrantz   And the 4-tab socket. Damned stuff was very sneak...   Dec 28 2020, 08:10 PM
bkrantz   At least the wax in the big holes worked.   Dec 28 2020, 08:11 PM
bkrantz   And was easy to clean out with a tooth pick, Q-tip...   Dec 28 2020, 08:12 PM
bkrantz   Ready to go! A few lessons: To fill the unde...   Dec 28 2020, 08:16 PM
bkrantz   One more task done today: a new shift rod bushing ...   Dec 28 2020, 08:18 PM
bkrantz   This was a bit difficult to install. I tried pres...   Dec 28 2020, 08:21 PM
bkrantz   Next, mounting new air deflectors.   Dec 29 2020, 07:40 PM
mb911   @bkrantz there was something that left here today...   Dec 29 2020, 07:42 PM
bkrantz   Three holes on the right side, that match the cent...   Dec 29 2020, 07:42 PM
bkrantz   And 3 holes on the left. Note the parking brake t...   Dec 29 2020, 07:45 PM
bkrantz   The bolts screw into under-sized holes in the plas...   Dec 29 2020, 07:48 PM
bkrantz   Left side in place.   Dec 29 2020, 07:49 PM
bkrantz   And right side.   Dec 29 2020, 07:50 PM
bkrantz   Note the factory manual has a page about mounting ...   Dec 29 2020, 07:53 PM
bkrantz   A couple of weeks ago, before installing the wirin...   Dec 30 2020, 07:56 PM
bbrock   A couple of weeks ago, before installing the wiri...   Jan 3 2021, 12:14 AM
bkrantz   Half the connector stays with the harness.   Dec 30 2020, 07:56 PM
bkrantz   The other half stays with the switch, which needs ...   Dec 30 2020, 07:57 PM
bkrantz   Here's the column control module, with the ori...   Dec 30 2020, 08:02 PM
bkrantz   The CarMagic switch replaces the fluid valve, but ...   Dec 30 2020, 08:05 PM
bkrantz   I decided to cut off the narrow end of the switch ...   Dec 30 2020, 08:07 PM
bkrantz   To make this work, I need to get the switch to sit...   Dec 30 2020, 08:10 PM
bkrantz   With the switch mounted, I checked the function. ...   Dec 30 2020, 08:13 PM
jaredmcginness   You’ve left no bolt un-turned!!!   Dec 30 2020, 08:13 PM
bkrantz   Last detail: the mounting flange for the switch pr...   Dec 30 2020, 08:14 PM
bkrantz   Just a small air gap in "resting" state.   Dec 30 2020, 08:15 PM
bkrantz   And when the wiper/washer lever is pulled, it push...   Dec 30 2020, 08:18 PM
bkrantz   Control module inserted into steering column housi...   Dec 30 2020, 08:19 PM
djway   Very cool on the pump switch. I have been making t...   Dec 31 2020, 12:39 AM
930cabman   Very cool on the pump switch. I have been making ...   Dec 31 2020, 05:49 AM
wonkipop   @bkrantz just read your thread from wo to go over...   Dec 31 2020, 06:44 AM
bkrantz   Thanks, guys. Fun and therapeutic to share (and I...   Jan 2 2021, 09:27 AM
bkrantz   A few days ago, I made more progress with brakes, ...   Jan 2 2021, 09:29 AM
bkrantz   I also got the angled grommets for the brake fluid...   Jan 2 2021, 09:30 AM
bkrantz   And popped these in place.   Jan 2 2021, 09:31 AM
bkrantz   Now I installed the MC "for real".   Jan 2 2021, 09:32 AM
bkrantz   I also got and installed the circular retaining cl...   Jan 2 2021, 09:34 AM
raynekat   I also got and installed the circular retaining...   Jan 2 2021, 10:05 PM
bkrantz   With the MC installed, I adjusted and installed th...   Jan 2 2021, 09:35 AM
bkrantz   Then the front line to the right side.   Jan 2 2021, 09:36 AM
bkrantz   And the front line to the left. As expected, all ...   Jan 2 2021, 09:37 AM
bkrantz   Finally, the warning switch connectors and new boo...   Jan 2 2021, 09:39 AM
bkrantz   Done (I hope).   Jan 2 2021, 09:40 AM
bkrantz   While under the front, I decided to start some sus...   Jan 2 2021, 09:42 AM
bkrantz   I know my sequence is not normal, but it worked ou...   Jan 2 2021, 09:44 AM
bkrantz   And another rebuild personal milestone: first fast...   Jan 2 2021, 09:45 AM
bkrantz   I then snuck the rack up into place, with reasonab...   Jan 2 2021, 09:47 AM
bkrantz   I then installed the front suspension carrier cros...   Jan 2 2021, 09:48 AM
bkrantz   And then discovered I forgot this. Recognize it?   Jan 2 2021, 09:49 AM
bkrantz   This is the big rubber grommet that seals the fron...   Jan 2 2021, 09:50 AM
bkrantz   With everything back in place I installed the shaf...   Jan 2 2021, 09:51 AM
bkrantz   Yesterday, I kept going on the front suspension. ...   Jan 2 2021, 09:54 AM
bkrantz   Top view   Jan 2 2021, 09:54 AM
bkrantz   A-arm installed. This is starting to look like so...   Jan 2 2021, 09:55 AM
bkrantz   And the front A-arm cap. I did not get the correc...   Jan 2 2021, 09:56 AM
raynekat   And the front A-arm cap. I did not get the corre...   Jan 2 2021, 10:03 PM
bkrantz   Here's a sneak preview of the interior. My so...   Jan 2 2021, 07:54 PM
bkrantz   Definitely not stock! The look is black vinyl...   Jan 2 2021, 07:56 PM
bkrantz   And the same on the door panels.   Jan 2 2021, 08:03 PM
bkrantz   With recent parts delivery, I got back to the shif...   Jan 3 2021, 07:31 PM
bkrantz   And the socket in main bracket.   Jan 3 2021, 07:34 PM
bkrantz   Here's the lever in place (upside down).   Jan 3 2021, 07:35 PM
bkrantz   And the sliding plate.   Jan 3 2021, 07:36 PM
bkrantz   The springs for the sliding plate turned out to be...   Jan 3 2021, 07:37 PM
bkrantz   And I could use the new circlips, and lock the pin...   Jan 3 2021, 07:39 PM
bkrantz   For the second spring, here's how I got in pla...   Jan 3 2021, 07:41 PM
bkrantz   Then I put one end of the spring on the pin.   Jan 3 2021, 07:43 PM
bkrantz   Even with the experience with the first spring, it...   Jan 3 2021, 07:45 PM
bkrantz   Finally, I greased and added the bottom lever.   Jan 3 2021, 07:46 PM
bkrantz   And then installed the gear shift in the car.   Jan 3 2021, 07:48 PM
bkrantz   I had more time, so I went back to the new parts b...   Jan 3 2021, 07:50 PM
bkrantz   And screwed them in place.   Jan 3 2021, 07:52 PM
bkrantz   That inspired me to get the left strut. I had to ...   Jan 3 2021, 07:54 PM
bkrantz   And the new Bilstein insert.   Jan 3 2021, 07:55 PM
bkrantz   Fits perfectly, and all tightened up.   Jan 3 2021, 07:56 PM
bkrantz   Here's the strut top hardware, including new 2...   Jan 3 2021, 07:57 PM
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