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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   Cover installed, with new sealing nuts.   Aug 28 2021, 07:57 PM
bkrantz   And then the impeller hub and crank nose seal.   Aug 28 2021, 07:59 PM
bkrantz   Before installing the hub, I dressed the sealing s...   Aug 28 2021, 08:00 PM
bkrantz   I also cleaned up the small Woodruff key.   Aug 28 2021, 08:01 PM
bkrantz   Seal and hub installed.   Aug 28 2021, 08:02 PM
930cabman   Bob, what grit did you use to clean the sealing su...   Aug 29 2021, 10:32 AM
bkrantz   Bob, what grit did you use to clean the sealing s...   Aug 29 2021, 07:45 PM
iankarr   Did you put the o-ring around the nose of the cran...   Aug 29 2021, 10:52 AM
bkrantz   Did you put the o-ring around the nose of the cra...   Aug 29 2021, 08:08 PM
iankarr   Got your six :) though in this group that could ta...   Aug 30 2021, 07:54 AM
bkrantz   I also realized I forgot a couple of the oil galle...   Aug 29 2021, 08:12 PM
bkrantz   And the remaining NPT plugs in the kit.   Aug 29 2021, 08:13 PM
bkrantz   After some thread sealant...   Aug 29 2021, 08:14 PM
bkrantz   Both plugs are in place.   Aug 29 2021, 08:14 PM
bkrantz   Now I have one very small plug left over. I don...   Aug 29 2021, 08:16 PM
930cabman   Now I have one very small plug left over. I don...   Aug 30 2021, 07:16 AM
bkrantz   Now I have one very small plug left over. I don...   Aug 31 2021, 08:39 PM
bkrantz   My next project is creating and installing a new o...   Aug 29 2021, 08:17 PM
bkrantz   I bought a 1mm and then a 0.5mm wall tube, both 8m...   Aug 29 2021, 08:18 PM
bkrantz   That was based on my measurement of the original t...   Aug 29 2021, 08:19 PM
bkrantz   But the part that inserts into the engine case is ...   Aug 29 2021, 08:21 PM
930cabman   Bob, have a look at post # 3605, it would be dire...   Sep 3 2021, 05:50 AM
bkrantz   Bob, have a look at post # 3605, it would be dir...   Sep 3 2021, 07:36 PM
raynekat   Bob....did anyone ever tell you that you act like ...   Sep 3 2021, 08:51 PM
bkrantz   Bob....did anyone ever tell you that you act like...   Sep 4 2021, 07:35 PM
bkrantz   Speaking of which, I tried again to make my new oi...   Sep 4 2021, 07:37 PM
bkrantz   Got my bench grinder onto my bench. Some day in m...   Sep 4 2021, 07:40 PM
bkrantz   I ground the end of the 7.4 mm rod, so I can use i...   Sep 4 2021, 07:42 PM
bkrantz   I first tried to force the rod into the tubing col...   Sep 4 2021, 07:44 PM
bkrantz   That worked, especially after I refined my techniq...   Sep 4 2021, 07:45 PM
bkrantz   But the end result was too much enlargement. I nee...   Sep 4 2021, 07:47 PM
bkrantz   Still waiting for several parts to arrive, so I ca...   Sep 5 2021, 08:53 PM
bkrantz   Here is my current plan: mounting the antenna pad ...   Sep 5 2021, 08:54 PM
bkrantz   The wire goes along the A-pillar.   Sep 5 2021, 08:54 PM
bkrantz   And through the gap at the side of the dashboard.   Sep 5 2021, 08:55 PM
bkrantz   I re-installed the A-pllar pad, the left the anten...   Sep 5 2021, 08:57 PM
bkrantz   At the bottom end, I connected the antenna lead. ...   Sep 5 2021, 08:58 PM
bkrantz   And then I worked on the replacement console panel...   Sep 5 2021, 09:03 PM
bkrantz   Not my neatest effort, but I got the vinyl glued o...   Sep 5 2021, 09:04 PM
bkrantz   Once everything dries, I will clean up the mess wi...   Sep 5 2021, 09:06 PM
930cabman   Looks great, how close is the vinyl to the origina...   Sep 6 2021, 05:15 AM
bkrantz   Looks great, how close is the vinyl to the origin...   Sep 6 2021, 06:58 PM
raynekat   Meant to say you're one of them "earth...   Sep 6 2021, 05:06 PM
bkrantz   Meant to say you're one of them "earth...   Sep 6 2021, 06:58 PM
bkrantz   I cleaned up both sides, first with 3M and then a ...   Sep 6 2021, 07:00 PM
bkrantz   This should do.   Sep 6 2021, 07:01 PM
bkrantz   I spent some time refining fits. Here is the left...   Sep 8 2021, 07:39 PM
bkrantz   This is better, and the best I can do without enla...   Sep 8 2021, 07:40 PM
bkrantz   I then tackled the sagging hood. Initially, I put...   Sep 8 2021, 07:41 PM
bkrantz   I put my special tool back together, and moved the...   Sep 8 2021, 07:42 PM
bkrantz   Now the hood stays up.   Sep 8 2021, 07:43 PM
bkrantz   I found a problem with the console shift panel. T...   Sep 9 2021, 07:47 PM
bkrantz   To keep the clip down, I teased open the vinyl alo...   Sep 9 2021, 07:49 PM
bkrantz   The last thing I need to do is attach the shift le...   Sep 9 2021, 07:51 PM
Morph914   I think I have a decent one, I can take pictures f...   Sep 9 2021, 08:15 PM
bkrantz   I think I have a decent one, I can take pictures ...   Sep 9 2021, 09:27 PM
Morph914   I thought I had the leather boot, but this is wha...   Sep 10 2021, 10:37 AM
bkrantz   I thought I had the leather boot, but this is wh...   Sep 10 2021, 07:09 PM
Morph914   Headed your way, pm sent   Sep 11 2021, 03:41 PM
bkrantz   I got my 7.2 and 7.3 mm rods, so I went back to ma...   Sep 11 2021, 07:09 PM
bkrantz   Like last time, I ground a short taper into one en...   Sep 11 2021, 07:11 PM
bkrantz   I cut the tube to length, and then made a flare at...   Sep 11 2021, 07:13 PM
bkrantz   The new tube is not perfect, but I like it better ...   Sep 11 2021, 07:13 PM
bkrantz   Just to test, it seems like a properly snug fit in...   Sep 11 2021, 07:15 PM
bkrantz   A different topic today: new custom floor panel fo...   Sep 12 2021, 06:45 PM
bkrantz   Laying out based on my cardboard template, with a ...   Sep 12 2021, 06:46 PM
bkrantz   And then time to get out some tools that I seldom ...   Sep 12 2021, 06:47 PM
bkrantz   All finished with rough cutting.   Sep 12 2021, 06:50 PM
bkrantz   I decided to make the floor float over the spare t...   Sep 12 2021, 06:52 PM
bkrantz   I mounted the supports on either side, with heavy ...   Sep 12 2021, 06:53 PM
bkrantz   Here's how the floor panel fits. I plan to co...   Sep 12 2021, 06:54 PM
bkrantz   A check on the spare tire space: almost 7 inches d...   Sep 12 2021, 06:56 PM
iankarr   Awesome idea and work, as usual. You should offer ...   Sep 13 2021, 07:12 AM
bkrantz   Thanks, Ian. But that would be too much like work...   Sep 13 2021, 07:03 PM
bkrantz   Since my new heads are due to arrive this week, I ...   Sep 13 2021, 07:07 PM
bkrantz   At least the new hub retaining bolts arrived, with...   Sep 13 2021, 07:09 PM
bkrantz   Seems like the right O-ring.   Sep 13 2021, 07:09 PM
bkrantz   Hub installed and torqued.   Sep 13 2021, 07:10 PM
bkrantz   I dug around in the box of miscellaneous engine pa...   Sep 13 2021, 07:12 PM
bkrantz   Sender, with seal rings old and new.   Sep 13 2021, 07:13 PM
bkrantz   Sender installed.   Sep 13 2021, 07:14 PM
bkrantz   Cover with grommet (not yet poked for a hole) and ...   Sep 13 2021, 07:15 PM
bkrantz   Cover installed temporarily. I will make a new le...   Sep 13 2021, 07:16 PM
bkrantz   I also found a spare 8 mm copper washer.   Sep 13 2021, 07:17 PM
bkrantz   That seals up the distributor bracket hole. Not n...   Sep 13 2021, 07:19 PM
bkrantz   One more project today: making an adjustable pushr...   Sep 13 2021, 07:20 PM
bkrantz   As many people have done before, it was easy to ru...   Sep 13 2021, 07:21 PM
bkrantz   Ready to use.   Sep 13 2021, 07:22 PM
bkrantz   Back to work on the frunk floor panel. Here it is...   Sep 14 2021, 07:37 PM
bkrantz   And painted.   Sep 14 2021, 07:38 PM
bkrantz   Once I get Perlon material, I will cover the top s...   Sep 14 2021, 07:39 PM
bkrantz   Big day: installing the first part of the Dubshop ...   Sep 15 2021, 07:15 PM
bkrantz   First attempt to fit the toothed wheel, and the ce...   Sep 15 2021, 07:18 PM
bkrantz   Some light filing and smoothing, and...   Sep 15 2021, 07:18 PM
bkrantz   It now slides onto the hub, but it rocks a bit and...   Sep 15 2021, 07:21 PM
bkrantz   After some rounds of light hammering and checking,...   Sep 15 2021, 07:23 PM
bkrantz   Next, I mounted the sensor to the supplied bracket...   Sep 15 2021, 07:24 PM
bkrantz   The bracket mounts using two of the case edge bolt...   Sep 15 2021, 07:26 PM
bkrantz   The desired clearance is less than 3 mm, and I aim...   Sep 15 2021, 07:29 PM
bkrantz   I got about 1.8 mm.   Sep 15 2021, 07:29 PM
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