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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 I did the same on the right side.   Jul 21 2021, 06:53 PM
bkrantz   Time for a new white board list. Engine stuff sti...   Jul 21 2021, 06:54 PM
bkrantz   New hose and grommet stock!   Jul 22 2021, 07:14 PM
bkrantz   Grommets are for the same hole size (20-22 mm) but...   Jul 22 2021, 07:16 PM
bkrantz   Plumbing done in fender well.   Jul 22 2021, 07:16 PM
bkrantz   And along the rocker.   Jul 22 2021, 07:17 PM
bkrantz   Into the engine compartment.   Jul 22 2021, 07:18 PM
bkrantz   And by the fuel tank.   Jul 22 2021, 07:19 PM
bkrantz   Then I got out the rocker covers. They are a litt...   Jul 22 2021, 07:20 PM
bkrantz   I used stainless screws so I can easily open thing...   Jul 22 2021, 07:22 PM
bkrantz   Left side on, and now I can finish the fender line...   Jul 22 2021, 07:23 PM
bkrantz   I started on the left rear fender liner. I modifie...   Jul 23 2021, 07:06 PM
bkrantz   Leading edge clip in place.   Jul 23 2021, 07:09 PM
bkrantz   On the trailing edge, the clip just reaches the ho...   Jul 23 2021, 07:10 PM
bkrantz   Test fitting the liner. It sits snugly against th...   Jul 23 2021, 07:13 PM
bkrantz   Time to use some 1/8" rubber sheet, pop-rivet...   Jul 23 2021, 07:16 PM
bkrantz   Of course, today my rivet tool choked on one of th...   Jul 23 2021, 07:19 PM
bkrantz   First fitting attempt: a bit wobbly.   Jul 23 2021, 07:20 PM
bkrantz   Second attempt: some slits, and the flaps lay tigh...   Jul 23 2021, 07:22 PM
bkrantz   Of course, fussing with the rear side made me thin...   Jul 23 2021, 07:24 PM
bkrantz   Maybe something like this? I need bigger rubber s...   Jul 23 2021, 07:27 PM
bkrantz   For now, it looks like this.   Jul 23 2021, 07:29 PM
bkrantz   The last thing I did today was mount the right sid...   Jul 23 2021, 07:30 PM
bkrantz   Next interior bit: speakers and pods. I decided t...   Jul 24 2021, 07:16 PM
bkrantz   Here's how the left side fits, with limited sp...   Jul 24 2021, 07:18 PM
bkrantz   I got these Infinity plate speakers, which should ...   Jul 24 2021, 07:20 PM
bkrantz   The right side box sits too high for the screw hol...   Jul 25 2021, 07:17 PM
bkrantz   I used a new utility blade to shave about 1.5 mm o...   Jul 25 2021, 07:18 PM
bkrantz   That was enough for things to line up.   Jul 25 2021, 07:21 PM
bkrantz   Now to develop some speaker mounting adapters.   Jul 25 2021, 07:23 PM
bkrantz   I made these from 1/4" MDF. Once I get some ...   Jul 25 2021, 07:25 PM
bkrantz   Here is my first version: the mounting board sits ...   Jul 26 2021, 07:00 PM
bkrantz   That leaves almost 1/2" between the grill and...   Jul 26 2021, 07:01 PM
bkrantz   It does sorta fit, by bending the pod a bit.   Jul 26 2021, 07:02 PM
bkrantz   Here's the problem: the magnet of the mid-rang...   Jul 26 2021, 07:04 PM
bkrantz   Here is version 2. Like Brent, I moved the mounti...   Jul 26 2021, 07:13 PM
bkrantz   Modified boards, repainted.   Jul 26 2021, 07:14 PM
bkrantz   One more mod: for the speaker to sit closer to the...   Jul 26 2021, 07:16 PM
bkrantz   So, a quick trim of the speaker plate. Original o...   Jul 26 2021, 07:17 PM
bkrantz   Now the speaker fits between the studs, and can si...   Jul 26 2021, 07:18 PM
bkrantz   So now the speaker and the pod mount to the same s...   Jul 26 2021, 07:20 PM
bkrantz   Now the speaker magnet protrudes just a little bit...   Jul 26 2021, 07:22 PM
bkrantz   With the tweeter down, the mid range magnet almost...   Jul 26 2021, 07:23 PM
bkrantz   The paper template shows where the magnet projects...   Jul 26 2021, 07:24 PM
bkrantz   Just a quick bit of hammer work to ease the lower ...   Jul 26 2021, 07:26 PM
bkrantz   A bit of paint touch-up.   Jul 26 2021, 07:28 PM
bkrantz   Everything fits, and the speaker magnet does not c...   Jul 26 2021, 07:31 PM
bkrantz   I counter-sunk the holes on the front of the speak...   Jul 28 2021, 08:13 PM
bkrantz   Speaker mounted to board.   Jul 28 2021, 08:14 PM
bkrantz   Board and speaker mounted to pod.   Jul 28 2021, 08:15 PM
bkrantz   Pod, board, and speaker mounted to car.   Jul 28 2021, 08:16 PM
djway   Rock On   Jul 28 2021, 10:05 PM
bkrantz   Rock On Now I just need a source!   Jul 29 2021, 09:19 PM
djway   Rock On Now I just need a source! I'm...   Jul 30 2021, 10:36 PM
bkrantz   [quote name='bkrantz' post='2934255' date='Jul 29...   Jul 31 2021, 08:30 PM
bkrantz   Today, I played with the frunk floor, starting wit...   Jul 29 2021, 09:21 PM
bkrantz   First, I undid some PO staples along the rear edge...   Jul 29 2021, 09:24 PM
bkrantz   After I removed all the perlon, I exposed the plyw...   Jul 29 2021, 09:27 PM
bkrantz   But it looks just a little warped.   Jul 29 2021, 09:28 PM
bkrantz   The OE plywood fits almost precisely sitting on th...   Jul 29 2021, 09:30 PM
bkrantz   Speaking of spares, this is what came in my car, a...   Jul 29 2021, 09:32 PM
bkrantz   That's some serious tread--almost 4 inches wid...   Jul 29 2021, 09:33 PM
bkrantz   Here's what I am thinking about: a larger plyw...   Jul 29 2021, 09:35 PM
Puebloswatcop   I really like the idea for the new frunk floor, I ...   Jul 30 2021, 07:20 AM
bkrantz   I really like the idea for the new frunk floor, I...   Jul 30 2021, 06:57 PM
bkrantz   More hardware arrived, so I can finished my fender...   Jul 31 2021, 08:32 PM
bkrantz   Here is the right rear liner, with my rubber shiel...   Jul 31 2021, 08:33 PM
bkrantz   Liner installed. If you missed my earlier posts, ...   Jul 31 2021, 08:34 PM
bkrantz   Then a bit of trivia. I dug out the jack tube cov...   Jul 31 2021, 08:36 PM
bkrantz   After a bit of clean-up.   Jul 31 2021, 08:37 PM
bkrantz   I finally got out the targa top. The outside actu...   Jul 31 2021, 08:47 PM
bkrantz   At some time, a PO had it covered with vinyl. It ...   Jul 31 2021, 08:48 PM
bkrantz   But the vinyl is pulling away, especially along th...   Jul 31 2021, 08:50 PM
bkrantz   Inside, the front latches and pad look OK.   Jul 31 2021, 08:51 PM
bkrantz   But most of the rubber, and one mounting block are...   Jul 31 2021, 08:52 PM
bkrantz   Here's the inside all stripped. I will take t...   Jul 31 2021, 08:54 PM
bkrantz   Detail of the PO vinyl covering, wrapped over the ...   Aug 1 2021, 06:43 PM
bkrantz   I undid the various glues: contact cement over the...   Aug 1 2021, 06:45 PM
bkrantz   Pulling the vinyl off. Surprise! Some earlie...   Aug 1 2021, 06:46 PM
bkrantz   De-skinned. More damage spots and lots of dried u...   Aug 1 2021, 06:48 PM
bkrantz   After an hour with a brass wire brush. Next, I wi...   Aug 1 2021, 06:50 PM
raynekat   After an hour with a brass wire brush. Next, I w...   Aug 3 2021, 11:02 PM
bkrantz   [quote name='bkrantz' post='2934914' date='Aug 1 ...   Aug 4 2021, 08:58 PM
bkrantz   While waiting to get my engine case back, I found ...   Aug 2 2021, 07:51 PM
bkrantz   I did both sides, plus seam across the floor betwe...   Aug 2 2021, 07:56 PM
bkrantz   My engine case is back in the house (garage actual...   Aug 3 2021, 07:26 PM
bkrantz   George and crew did the decking, with a wide enoug...   Aug 3 2021, 07:28 PM
bkrantz   And also did a line bore, to 0.25 mm oversize. No...   Aug 3 2021, 07:30 PM
bkrantz   I got out all the studs I had removed and cleaned.   Aug 3 2021, 07:31 PM
bkrantz   And I got started installing the studs in the case...   Aug 3 2021, 07:32 PM
djway   Did you remember to get your thrust bearing cut?   Aug 3 2021, 11:48 PM
autopro   The work on your engine looks great. I just took ...   Aug 4 2021, 09:39 AM
bkrantz   I got to work today, since I want to get the engin...   Aug 4 2021, 09:06 PM
bkrantz   Then the threaded plugs.   Aug 4 2021, 09:07 PM
bkrantz   Engine case halves ready.   Aug 4 2021, 09:08 PM
bkrantz   And the right half mounted on the stand again.   Aug 4 2021, 09:08 PM
bkrantz   Now to replace the #3 bearing. This is from my pr...   Aug 4 2021, 09:15 PM
bkrantz   Since I did not want to remove the con rods, and d...   Aug 4 2021, 09:17 PM
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