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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 time for the cam bearings. I have a full set...   May 3 2021, 07:25 PM
bkrantz   Cam bearings installed in the right case half.   May 3 2021, 07:26 PM
bkrantz   Cam installed.   May 3 2021, 07:27 PM
bkrantz   Gears indexed--probably the easiest step in the en...   May 3 2021, 07:28 PM
bkrantz   And cam bearings in the left case half. This is w...   May 3 2021, 07:29 PM
bkrantz   I got out my new oil pump, a Shradek 26mm.   May 4 2021, 06:57 PM
bkrantz   And slid the pump into place, with the cam as I le...   May 4 2021, 06:59 PM
bkrantz   And found contact between the bolt heads and the p...   May 4 2021, 07:00 PM
bkrantz   So I pulled the cam R&R'd the bolts to omi...   May 4 2021, 07:02 PM
bkrantz   Cam and pump back in place.   May 4 2021, 07:03 PM
bkrantz   Now there is daylight between the bolt heads and t...   May 4 2021, 07:05 PM
bkrantz   I measured .042 inch clearance.   May 4 2021, 07:05 PM
bkrantz   But then found another problem. The rotor stud is...   May 4 2021, 07:07 PM
bkrantz   Checking the drive rotor, the shaft is not pushed ...   May 5 2021, 07:55 PM
bkrantz   A quick visit to the hydraulic press...   May 5 2021, 07:56 PM
bkrantz   Now the shaft is flush.   May 5 2021, 07:57 PM
bkrantz   I also checked the clearance of the oil pump case ...   May 5 2021, 07:58 PM
bkrantz   The depth of insertion of the pump case is 38.84 m...   May 5 2021, 08:00 PM
bkrantz   The deepest part of the case is the protrusion aro...   May 5 2021, 08:02 PM
bkrantz   I filed off the end of the protrusion (easy, since...   May 5 2021, 08:04 PM
bkrantz   Now the base of the notch extends beyond the case.   May 5 2021, 08:05 PM
bkrantz   Now the pump sits tight into the engine case, with...   May 5 2021, 08:08 PM
bkrantz   And the pump gears sit inside the case and do not ...   May 5 2021, 08:09 PM
bkrantz   To celebrate I cleaned up the case through-bolts, ...   May 5 2021, 08:10 PM
bkrantz   I found my left-over Dynamat, and decided to use s...   May 6 2021, 07:13 PM
bkrantz   After about 20 minutes. It might not matter much,...   May 6 2021, 07:14 PM
bkrantz   I then got on to installing the main gauge panel. ...   May 6 2021, 07:20 PM
bkrantz   First I replaced all the bulbs in the common back-...   May 6 2021, 07:21 PM
bkrantz   Here's my references for wire locations: photo...   May 6 2021, 07:25 PM
bkrantz   Ready to start!   May 6 2021, 07:26 PM
bkrantz   And then, done. I was able to find places for all...   May 6 2021, 07:28 PM
Kansas 914   And then, done. I was able to find places for al...   May 6 2021, 07:48 PM
bkrantz   And then, done. I was able to find places for a...   May 6 2021, 08:06 PM
bkrantz   And then I installed the gauge panel. I have a co...   May 6 2021, 07:30 PM
Puebloswatcop   Love following your build. It has been full of th...   May 7 2021, 07:08 AM
930cabman   Love following your build. It has been full of t...   May 7 2021, 01:00 PM
bkrantz   Love following your build. It has been full of ...   May 7 2021, 07:15 PM
Puebloswatcop   [quote name='930cabman' post='2914086' date='May ...   May 8 2021, 07:57 AM
bkrantz   I got some 50 mm hose, that almost matches the 60 ...   May 7 2021, 07:19 PM
mb911   I got some 50 mm hose, that almost matches the 60...   May 8 2021, 08:02 AM
bkrantz   [quote name='bkrantz' post='2914166' date='May 7 ...   May 8 2021, 08:04 PM
bkrantz   This is to connect the mixer boxes with the feed f...   May 7 2021, 07:20 PM
bkrantz   I did the left side, and with a bit of twisting, t...   May 7 2021, 07:21 PM
bkrantz   I got the right side vent hose installed. This on...   May 8 2021, 08:05 PM
bkrantz   With the reservoir installed, a tight but workable...   May 8 2021, 08:06 PM
bkrantz   I got out the side vents to finish up the system.   May 8 2021, 08:07 PM
bkrantz   They do not fit tightly into the dash front, and c...   May 8 2021, 08:08 PM
bkrantz   The problem is the retaining tabs. Most are not s...   May 8 2021, 08:09 PM
bkrantz   I got out my junk soldering iron, and applied a bi...   May 8 2021, 08:12 PM
bkrantz   All the tabs now stick out.   May 8 2021, 08:12 PM
bkrantz   And the vents snap tightly into the dash.   May 8 2021, 08:13 PM
bkrantz   Then I decided to complete the engine case assembl...   May 8 2021, 08:15 PM
bkrantz   And on the cam. This establishes a red theme for ...   May 8 2021, 08:16 PM
bkrantz   I replaced the oil pickup tube O-ring, and gave it...   May 8 2021, 08:17 PM
bkrantz   And installed the pickup.   May 8 2021, 08:18 PM
bkrantz   Then new rubber edge seals on the baffles.   May 8 2021, 08:19 PM
bkrantz   And installed that.   May 8 2021, 08:19 PM
bkrantz   Then came lots of cleaning of the mating surfaces ...   May 8 2021, 08:21 PM
bkrantz   I remembered the new cam plug.   May 8 2021, 08:22 PM
bkrantz   And I got out the case hardware.   May 8 2021, 08:23 PM
bkrantz   Here's the right case half with the through bo...   May 8 2021, 08:24 PM
bkrantz   As recommended by Dan at Competition Engineering, ...   May 8 2021, 08:27 PM
bkrantz   Which completes the red assembly theme.   May 8 2021, 08:28 PM
bkrantz   Cam plug installed. And I remembered to add more ...   May 8 2021, 08:29 PM
bkrantz   With all the hardware installed and torqued, the c...   May 8 2021, 08:32 PM
djway   :beer2:   May 8 2021, 09:51 PM
Puebloswatcop   :beer2: Awesome progress...Also glad you remembere...   May 9 2021, 09:23 AM
bkrantz   I almost forgot it, since I was maneuvering the le...   May 9 2021, 02:36 PM
bkrantz   Today was oil pump day. I have played with it so ...   May 9 2021, 02:38 PM
bkrantz   As expected, the case interferes with one corner o...   May 9 2021, 02:39 PM
bkrantz   A quick trim with a cut-off wheel and then some gr...   May 9 2021, 02:39 PM
bkrantz   But first I installed the pump body and gears. Th...   May 9 2021, 02:40 PM
bkrantz   I used the sealing pump nuts--not sure if really n...   May 9 2021, 02:41 PM
bkrantz   And then buttoned-up with the cover.   May 9 2021, 02:42 PM
pilothyer   wrong post   May 10 2021, 03:31 PM
iankarr   Awesome work, as usual. I also spent tons of time...   May 10 2021, 10:11 PM
bkrantz   Awesome work, as usual. I also spent tons of tim...   May 11 2021, 09:00 PM
bkrantz   Time to check the crankshaft end play. I started ...   May 15 2021, 07:44 PM
bkrantz   I have the 3 shims from the tear down.   May 15 2021, 07:45 PM
bkrantz   I installed 2 shims on the end of the crank.   May 15 2021, 07:47 PM
bkrantz   And then the new flywheel with the old bolts.   May 15 2021, 07:47 PM
bkrantz   When I went to tighten the flywheel bolts I rememb...   May 15 2021, 07:49 PM
bkrantz   It still works.   May 15 2021, 07:50 PM
bkrantz   With the bolts tight, I made sure the crank had so...   May 15 2021, 07:52 PM
bkrantz   And then shifted the crank. I repeated this about...   May 15 2021, 07:54 PM
bkrantz   For the desired play of .004", I need a third...   May 15 2021, 07:57 PM
bkrantz   Meanwhile, back to working on the body trim. I go...   May 15 2021, 08:00 PM
bkrantz   And got these installed so I can mount the aluminu...   May 15 2021, 08:02 PM
bkrantz   Here's the thin butyl strip material I found, ...   May 16 2021, 07:35 PM
bkrantz   New stainless screws.   May 16 2021, 07:36 PM
bkrantz   Trim strip installed with the later of butyl under...   May 16 2021, 07:37 PM
bkrantz   While in the trim mood, I got out the strips that ...   May 16 2021, 07:39 PM
bkrantz   More new stainless screws.   May 16 2021, 07:39 PM
bkrantz   Trim installed with butyl.   May 16 2021, 07:40 PM
bkrantz   One last detail today: new ski rack tab receivers.   May 16 2021, 07:41 PM
bkrantz   Installed in the windshield frame top.   May 16 2021, 07:42 PM
bkrantz   I got a long day in the garage today, starting wit...   May 23 2021, 07:15 PM
bkrantz   A light smear of assembly lube, and I put the pist...   May 23 2021, 07:17 PM
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