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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   Followed by the retaining screw cap with a new cru...   May 23 2021, 07:18 PM
bkrantz   Then I got out the large diameter pressure relief ...   May 23 2021, 07:19 PM
bkrantz   I also found the tool I made to fit the bit slot o...   May 23 2021, 07:21 PM
bkrantz   With a new case bolt for the oil pick-up and strai...   May 23 2021, 07:22 PM
bkrantz   Done.   May 23 2021, 07:24 PM
bkrantz   Along with that bolt, I got shiny new hardware for...   May 23 2021, 07:25 PM
bkrantz   A bit of bling for the engine case.   May 23 2021, 07:26 PM
bkrantz   Then the oil strainer.   May 23 2021, 07:27 PM
bkrantz   Strainer basket with a gasket above and below.   May 23 2021, 07:28 PM
bkrantz   Strainer cover, retaining nut, and drain plug, all...   May 23 2021, 07:35 PM
bkrantz   Then the taco plate, for the oil temp sensor.   May 23 2021, 07:36 PM
bkrantz   Installed (without cover for now).   May 23 2021, 07:37 PM
bkrantz   I also got the tiny LED bulbs for the indicator li...   May 23 2021, 07:40 PM
bkrantz   But these have positive and negative leads that be...   May 23 2021, 07:40 PM
bkrantz   But the sockets have negative and positive leads o...   May 23 2021, 07:42 PM
bkrantz   So I re-bent the leads on the bulb to keep each po...   May 23 2021, 07:44 PM
bkrantz   With that mod, I inserted bulbs into the 2 sockets...   May 23 2021, 07:44 PM
bkrantz   And put those into the left and right side of the ...   May 23 2021, 07:45 PM
bkrantz   Next, I got out the heat control lever and cable. ...   May 23 2021, 07:46 PM
bkrantz   I fed the cable ends into the tubes in the tunnel,...   May 23 2021, 07:49 PM
bkrantz   Then connected the lead for the lever switch.   May 23 2021, 07:50 PM
bkrantz   And then installed the lever.   May 23 2021, 07:51 PM
bkrantz   Here's the indicator light for the heater leve...   May 23 2021, 07:54 PM
bkrantz   This will also need a modified LED bulb.   May 23 2021, 07:55 PM
bkrantz   Finally, I got out the license plate lights to cle...   May 23 2021, 07:56 PM
bkrantz   One of the lights has a couple of cracks. Time fo...   May 24 2021, 07:06 PM
bkrantz   Glued and clamped.   May 24 2021, 07:06 PM
bkrantz   New LED bulbs.   May 24 2021, 07:07 PM
bkrantz   Assembled and attached.   May 24 2021, 07:09 PM
bkrantz   Then I dug out the bag with the parking brake, and...   May 24 2021, 07:10 PM
bkrantz   Attached to the lead.   May 24 2021, 07:11 PM
bkrantz   And installed. All part of my plan to test the el...   May 24 2021, 07:12 PM
bkrantz   I then got out the cylinder heads. I knew I had s...   May 24 2021, 07:15 PM
bkrantz   One head is missing a stud, with an oversized hole...   May 24 2021, 07:16 PM
bkrantz   The other head also has a missing stud, but the or...   May 24 2021, 07:21 PM
bkrantz   However, it also has another odd stud. It seemed ...   May 24 2021, 07:22 PM
bkrantz   I screwed a bolt into the hole. The bolt (backgro...   May 24 2021, 07:24 PM
bkrantz   Looks like the hole with the bad angle has an inse...   May 24 2021, 07:28 PM
Puebloswatcop   Looks like the hole with the bad angle has an ins...   May 25 2021, 01:42 PM
bkrantz   Looks like the hole with the bad angle has an in...   May 25 2021, 06:50 PM
Lilchopshop   Looks like the hole with the bad angle has an ins...   May 26 2021, 07:10 AM
bkrantz   Looks like the hole with the bad angle has an in...   May 26 2021, 09:08 PM
bkrantz   More electrical bits today. I got out and cleaned...   May 25 2021, 06:51 PM
bkrantz   And connected the leads. Left side.   May 25 2021, 06:52 PM
bkrantz   And right.   May 25 2021, 06:52 PM
bkrantz   Some new rubber boots and screws.   May 25 2021, 06:53 PM
bkrantz   Looks tidy now.   May 25 2021, 06:54 PM
bkrantz   I re-engineered the interior light a bit.   May 25 2021, 06:56 PM
bkrantz   And connected the existing leads. Note that I hav...   May 25 2021, 06:57 PM
bkrantz   I plan to make a filler for the ash tray slot, and...   May 25 2021, 06:58 PM
bkrantz   I opened the box with the rest of the wiring harne...   May 25 2021, 06:59 PM
bkrantz   The good(-ish), the harness for the starter, coil,...   May 25 2021, 07:01 PM
bkrantz   The bad. The harness for the alternator. Intact,...   May 25 2021, 07:02 PM
bkrantz   And the ugly. The stock EFI harness. Fortunately...   May 25 2021, 07:03 PM
bkrantz   I plugged the connectors into the relay board, and...   May 25 2021, 07:04 PM
bbrock   I plugged the connectors into the relay board, an...   May 26 2021, 07:16 AM
bkrantz   I plugged the connectors into the relay board, a...   May 26 2021, 09:11 PM
djway   SHOCKING......... to realize your car is yellow ;...   May 25 2021, 09:26 PM
Puebloswatcop   Everything is looking awesome....   May 26 2021, 04:41 PM
bkrantz   Everything is looking awesome.... Thanks. Stil...   May 26 2021, 09:13 PM
bkrantz   The outsource saga continues. I brought my cylind...   Jun 2 2021, 09:04 PM
bkrantz   Home again, and time to work on more electrical th...   Jun 4 2021, 07:34 PM
bkrantz   Here's the old base, with the positive tab rem...   Jun 4 2021, 07:35 PM
bkrantz   And here's my first attempt, with a collar aro...   Jun 4 2021, 07:37 PM
bkrantz   Second attempt, after I could not get the copper p...   Jun 5 2021, 07:11 PM
bkrantz   Sockets complete, with new LED bulbs. If these ar...   Jun 5 2021, 07:13 PM
bkrantz   Now to sort through and select the best parts from...   Jun 5 2021, 07:15 PM
bkrantz   Plus new lenses.   Jun 5 2021, 07:15 PM
bkrantz   And new gaskets.   Jun 5 2021, 07:16 PM
bkrantz   Modified bulb holder installed.   Jun 5 2021, 07:17 PM
bkrantz   Rubber grommet in housing.   Jun 5 2021, 07:18 PM
bkrantz   One complete light.   Jun 5 2021, 07:18 PM
bkrantz   And it works!   Jun 5 2021, 07:19 PM
bkrantz   And installed for testing. Ignore the temporary e...   Jun 5 2021, 07:19 PM
bkrantz   With the fog lights installed, it was almost time ...   Jun 5 2021, 07:21 PM
bkrantz   And some engine components: coil, alternator, star...   Jun 5 2021, 07:22 PM
bkrantz   Time to connect a battery.   Jun 5 2021, 07:23 PM
bkrantz   As soon as I connected both battery leads, the hea...   Jun 5 2021, 07:25 PM
bkrantz   As soon as I connected both battery leads, the hea...   Jun 5 2021, 07:25 PM
bkrantz   I then started testing various components, with th...   Jun 5 2021, 07:32 PM
bkrantz   Things not (yet!) correct: Some lights (gauge...   Jun 5 2021, 07:39 PM
930cabman   Looking good, isn't it great when you power a ...   Jun 6 2021, 06:08 PM
bkrantz   Looking good, isn't it great when you power a...   Jun 6 2021, 07:21 PM
bkrantz   More electrical gremlin hunting today. First the ...   Jun 6 2021, 07:30 PM
bkrantz   But, the right headlight assembly made contact wit...   Jun 6 2021, 07:32 PM
bkrantz   Now I get to buy another pivot!   Jun 6 2021, 07:33 PM
bkrantz   I fixed the connections on the right tail light, s...   Jun 6 2021, 07:37 PM
bkrantz   And I jumped the leads for the reverse switch, and...   Jun 6 2021, 07:38 PM
bkrantz   Some fiddling with the socket base, and the front ...   Jun 6 2021, 07:39 PM
bkrantz   I ran power to the starter, and turned the key to ...   Jun 6 2021, 07:43 PM
bkrantz   I also checked (and fiddled with) the door contact...   Jun 6 2021, 07:50 PM
bkrantz   And success! I can switch from low to high be...   Jun 6 2021, 07:52 PM
bkrantz   I also hooked up the center console gauges, and al...   Jun 6 2021, 07:53 PM
bkrantz   One more known problem: although the turn signals ...   Jun 6 2021, 07:57 PM
bkrantz   According to Spoke, the problem is that the low cu...   Jun 6 2021, 07:59 PM
930cabman   Just an FYI: you may want to keep a can of "D...   Jun 7 2021, 01:20 PM
bkrantz   Just an FYI: you may want to keep a can of ...   Jun 7 2021, 07:07 PM
raynekat   Broke the headlight pivot.....yes those small elec...   Jun 7 2021, 05:20 PM
bkrantz   Broke the headlight pivot.....yes those small ele...   Jun 7 2021, 07:09 PM
bkrantz   I am feeling over the hump today. I reinstalled t...   Jun 7 2021, 07:10 PM
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