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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   Now time to move on. Here is the middle layer pat...   Feb 29 2020, 10:13 PM
bkrantz   And welded in place.   Feb 29 2020, 10:15 PM
bkrantz   And here is the top layer patch, nearly fitted.   Feb 29 2020, 10:16 PM
bkrantz   Started welding on the last layer, beginning with ...   Mar 1 2020, 09:36 PM
bkrantz   I ground down the welds along the flange and they ...   Mar 1 2020, 09:40 PM
bkrantz   I still have to grind this down and check the weld...   Mar 1 2020, 09:42 PM
tygaboy   A bit of :sawzall: :smash: :welder: And now s...   Mar 1 2020, 10:56 PM
bkrantz   Thanks. Milestones are good for my mental health,...   Mar 2 2020, 09:55 PM
bkrantz   On to the firewall. Here's a cardboard templa...   Mar 2 2020, 09:56 PM
bkrantz   Small patch cut and formed, with holes in the flan...   Mar 4 2020, 08:44 PM
bkrantz   Final fit.   Mar 4 2020, 08:45 PM
bkrantz   After welding and grinding. Now time for the bigg...   Mar 4 2020, 08:46 PM
bkrantz   And from the engine side.   Mar 4 2020, 08:47 PM
bkrantz   Spent about an hour today working on forming the u...   Mar 5 2020, 10:02 PM
FourBlades   Looking good! You are making good progress....   Mar 6 2020, 08:13 AM
9146C   Very impressed with your fabrication work!   Mar 6 2020, 09:20 AM
tygaboy   Fabricationlous! :smash: Nice looking patch p...   Mar 6 2020, 09:26 AM
bkrantz   Thank, guys. Just a bit of time to play body shop...   Mar 6 2020, 06:03 PM
bkrantz   Spent a couple of hours fitting the new patch. Af...   Mar 7 2020, 09:44 PM
bkrantz   And after tack-welding. Time for more patience.   Mar 7 2020, 09:45 PM
bkrantz   Welding done, and initial grinding. Might be a fe...   Mar 8 2020, 07:09 PM
bkrantz   On to the last thing in the hell hole area: the ri...   Mar 10 2020, 08:43 PM
bkrantz   First fit check after my initial trim. I need onl...   Mar 10 2020, 08:45 PM
bkrantz   And after about a dozen cycles of check, trim, ben...   Mar 10 2020, 08:46 PM
raynekat   Looks good Bob.   Mar 10 2020, 10:49 PM
bkrantz   Thanks, Doug. Still lots to do on the body shell ...   Mar 11 2020, 07:48 PM
bkrantz   Had a couple of hours of garage time and worked to...   Mar 12 2020, 08:25 PM
Lilchopshop   Bob, I'm really enjoying your thread! Th...   Mar 13 2020, 08:14 AM
tygaboy   I'm going to start calling you Bob "Dunwr...   Mar 13 2020, 08:42 AM
bkrantz   Thanks, guys. Encouragement always helps.   Mar 13 2020, 08:36 PM
bkrantz   Got the engine shelf welding done. I am pretty ha...   Mar 13 2020, 08:41 PM
bkrantz   On to the rest of the issues in the engine compart...   Mar 13 2020, 08:43 PM
bkrantz   After welding the grind the holes.   Mar 13 2020, 08:44 PM
bkrantz   And after measuring, and re-measuring, I tack-weld...   Mar 13 2020, 08:46 PM
bkrantz   Meanwhile, I started the next task. Both the left...   Mar 13 2020, 08:48 PM
bkrantz   Right side.   Mar 13 2020, 08:48 PM
bkrantz   I cut out just enough to get straight edges, and d...   Mar 13 2020, 08:50 PM
bkrantz   And right side. I will cut some patches tomorrow.   Mar 13 2020, 08:50 PM
bkrantz   When I measured the right trunk hinge bracket toda...   Mar 14 2020, 08:07 PM
bkrantz   Back to the engine lid hinges, here's the patc...   Mar 14 2020, 08:09 PM
bkrantz   And the right side.   Mar 14 2020, 08:11 PM
bkrantz   Left side bracket in position.   Mar 14 2020, 08:11 PM
bkrantz   And welded.   Mar 14 2020, 08:12 PM
bkrantz   And right side.   Mar 14 2020, 08:13 PM
raynekat   Yeah, those engine lid brackets need to be in the ...   Mar 14 2020, 08:56 PM
bkrantz   I will find out before too much longer. Before an...   Mar 15 2020, 08:19 PM
raynekat   I will find out before too much longer. Before a...   Mar 16 2020, 10:34 PM
bkrantz   Last task in the engine compartment area is dealin...   Mar 15 2020, 08:20 PM
bkrantz   Here's my favorite. How and why did somebody ...   Mar 15 2020, 08:21 PM
bkrantz   After straightening the sheet metal at some holes,...   Mar 15 2020, 08:24 PM
bkrantz   Looking ahead to the next job: repairing the sides...   Mar 15 2020, 08:27 PM
bkrantz   And the left side.   Mar 15 2020, 08:28 PM
bkrantz   But the left side had a surprise! First, some...   Mar 15 2020, 08:29 PM
bkrantz   And then LOTS of bondo on the cowl top surface, hi...   Mar 15 2020, 08:32 PM
bkrantz   Festival of holes, part 2, is done. I patched and...   Mar 16 2020, 09:03 PM
bkrantz   ...driver side firewall...   Mar 16 2020, 09:04 PM
bkrantz   ...and dash under-panel. Plus the front right inn...   Mar 16 2020, 09:05 PM
raynekat   Bob....seems like you're going to have a field...   Mar 16 2020, 10:35 PM
bkrantz   I try to spend time grinding as I go, but I have f...   Mar 17 2020, 08:28 PM
bkrantz   Speaking of grinding, at least bondo grinding, I d...   Mar 17 2020, 08:30 PM
bkrantz   I guess PO decided not to have a radio antenna.   Mar 17 2020, 08:33 PM
bkrantz   Got the Dremel tool out and cut the brazing. The ...   Mar 17 2020, 08:35 PM
bkrantz   And in keeping with PO repair quality, check the p...   Mar 17 2020, 08:37 PM
bkrantz   One more job for the grinder: the left front fende...   Mar 17 2020, 08:42 PM
bbrock   Am I seeing right that the antenna hole is in the ...   Mar 17 2020, 09:29 PM
bkrantz   Thats my guess for the purpose of the hole. Now y...   Mar 18 2020, 08:31 PM
bkrantz   Just a little time today to play 914, so I worked ...   Mar 18 2020, 08:37 PM
bkrantz   Finished the festival of holes, with step 3: grind...   Mar 19 2020, 08:17 PM
bkrantz   And the left side.   Mar 19 2020, 08:17 PM
bkrantz   And the dash under-panel.   Mar 19 2020, 08:18 PM
bkrantz   I also refilled the antenna hole in the right cowl...   Mar 19 2020, 08:20 PM
bkrantz   Welded in place.   Mar 19 2020, 08:21 PM
bkrantz   And after a quick grinding.   Mar 19 2020, 08:22 PM
FourBlades   Nice work as always! :) You are really good...   Mar 20 2020, 07:40 AM
bkrantz   Thanks. I have a copper spoon and use it whenever...   Mar 20 2020, 09:02 PM
bkrantz   I got to try my latest tool acquisition: a shrinki...   Mar 21 2020, 08:08 PM
bkrantz   I did this for about 20 minutes on the left side o...   Mar 21 2020, 08:10 PM
bkrantz   After the shrinking work, I decided to cut out a s...   Mar 21 2020, 08:11 PM
bkrantz   And I had time to fit a cardboard template for the...   Mar 21 2020, 08:12 PM
bkrantz   Translating cardboard into recycled 914 sheet meta...   Mar 22 2020, 08:11 PM
bkrantz   And after an hour of metal work, I had this. I ev...   Mar 22 2020, 08:13 PM
bkrantz   And fitted into place.   Mar 22 2020, 08:15 PM
bkrantz   While in the mood, I started on the last big job--...   Mar 22 2020, 08:18 PM
bkrantz   And a small patch ready for welding.   Mar 22 2020, 08:21 PM
bkrantz   MIG time today. First, the patch in the left side...   Mar 23 2020, 08:49 PM
bkrantz   Then a bit of grinding.   Mar 23 2020, 08:50 PM
bkrantz   And then another session with the shrinking disk, ...   Mar 23 2020, 08:51 PM
bkrantz   Then the right side, welding up the semi-rotten me...   Mar 23 2020, 08:52 PM
bkrantz   And ground down.   Mar 23 2020, 08:53 PM
bkrantz   Finally, the section of the fender mounting flange...   Mar 23 2020, 08:54 PM
bkrantz   Looking ahead, the next job is the last big task o...   Mar 23 2020, 08:56 PM
bkrantz   The fender needs a little work first, along the le...   Mar 23 2020, 08:57 PM
bkrantz   Got to work on the fender today. Here it is in a ...   Mar 24 2020, 07:43 PM
bkrantz   With the recess 90% straight, the next step is str...   Mar 24 2020, 07:45 PM
bkrantz   And with metal exposed, I can see what I need to f...   Mar 24 2020, 07:46 PM
bkrantz   Before any more metal work, I wanted to see how th...   Mar 25 2020, 08:10 PM
bkrantz   Another view.   Mar 25 2020, 08:10 PM
bkrantz   Besides dealing with the seam along the top, insid...   Mar 25 2020, 08:14 PM
bkrantz   Looking inside the fender, where it meets the moun...   Mar 25 2020, 08:16 PM
bkrantz   And from the back side of the A-pillar.   Mar 25 2020, 08:18 PM
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