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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
930cabman   Have you managed to check your piston to valve cle...   Sep 27 2021, 08:05 AM
bkrantz   Have you managed to check your piston to valve cl...   Sep 27 2021, 06:43 PM
bkrantz   And the exhaust valve.   Sep 27 2021, 06:44 PM
bkrantz   While waiting on shim steel, I played with another...   Sep 27 2021, 06:48 PM
bkrantz   Template just about done.   Sep 27 2021, 06:49 PM
bkrantz   Then I got out this roll of engine compartment ins...   Sep 27 2021, 06:50 PM
bkrantz   Or so I thought. At some time in the past, I cut ...   Sep 27 2021, 06:51 PM
bkrantz   My son picked up my rebuilt alternator.   Sep 28 2021, 08:49 PM
bkrantz   Work done at Tucson Alternator Exchange.   Sep 28 2021, 08:50 PM
bkrantz   Time to start another task:installing doors. Here...   Sep 29 2021, 07:43 PM
bkrantz   I decided to check the door fit before installing ...   Sep 29 2021, 07:44 PM
bkrantz   Left rear alignment and gap is pretty good.   Sep 29 2021, 07:45 PM
bkrantz   The right side is generally good. To be fussy the...   Sep 29 2021, 07:46 PM
bkrantz   After doing some "massaging" with a big ...   Sep 29 2021, 07:48 PM
bkrantz   Right rear gap and alignment looks good.   Sep 29 2021, 07:49 PM
bkrantz   On the left side, I elongated the upper hinge hole...   Sep 29 2021, 07:50 PM
bkrantz   The rear is sitting a little bit high, but I will ...   Sep 29 2021, 07:51 PM
bkrantz   Now the fun starts rebuilding the doors. Here is ...   Sep 29 2021, 07:52 PM
bkrantz   Next step: clean and install the window winders.   Sep 29 2021, 07:53 PM
Cairo94507   Those gaps look great. Your car is just beautiful...   Sep 30 2021, 06:55 AM
Puebloswatcop   Hey there Bob, after being gone for 10 days it wa...   Sep 30 2021, 07:18 AM
Dion   Car is looking good! Just a note. I was infor...   Sep 30 2021, 08:40 AM
bkrantz   Car is looking good! Just a note. I was info...   Sep 30 2021, 09:48 PM
bkrantz   Back home and back at 914 work. A few things got ...   Oct 6 2021, 08:01 PM
bkrantz   And the internal foam is closed-cell, so it can...   Oct 6 2021, 08:02 PM
bkrantz   New firewall blanket cut out.   Oct 6 2021, 08:04 PM
bkrantz   For attachment, I grabbed my high-strength Velcro.   Oct 6 2021, 08:05 PM
bkrantz   I stuck the hook side onto the car, and then velcr...   Oct 6 2021, 08:06 PM
bkrantz   This should help reduce heat transfer, and maybe n...   Oct 6 2021, 08:08 PM
Cairo94507   That came out really nice (not surprised) and I am...   Oct 7 2021, 07:24 AM
bkrantz   A little side job today. I plan to take my transa...   Oct 7 2021, 08:12 PM
bkrantz   Test fit. I will use the floor tie-downs and ratc...   Oct 7 2021, 08:14 PM
bkrantz   I then tried making shims for the rocker arm shaft...   Oct 7 2021, 08:18 PM
bkrantz   I cut 9 blanks to rough size, and then did some ma...   Oct 7 2021, 08:19 PM
bkrantz   Here are 9 blanks all finished, but lacking holes.   Oct 7 2021, 08:21 PM
bkrantz   I set up my drill press, but the vise shifted and ...   Oct 7 2021, 08:25 PM
bkrantz   Taking care of more details. I needed to make rep...   Oct 8 2021, 07:35 PM
bkrantz   When I had the seats recovered, they made new bott...   Oct 8 2021, 07:38 PM
bkrantz   I used some thin aluminum bar stock, to save, you ...   Oct 8 2021, 07:40 PM
bkrantz   Here's the initial shape.   Oct 8 2021, 07:41 PM
bkrantz   Test fit, with the new clip taped to the cushion b...   Oct 8 2021, 07:42 PM
bkrantz   The test showed the clip in the right location, bu...   Oct 8 2021, 07:45 PM
bkrantz   To attach the clips, I used some sheet metal screw...   Oct 8 2021, 07:46 PM
bkrantz   New clip in place.   Oct 8 2021, 07:46 PM
bkrantz   And...it works. The front of the cushion will not...   Oct 8 2021, 07:47 PM
bkrantz   And I made the same thing for the passenger side.   Oct 8 2021, 07:48 PM
bkrantz   I got some new 5/16 (8 mm) drill bits. I found Mi...   Oct 9 2021, 07:47 PM
bkrantz   Holes drilled in 8 shims with the proper offset.   Oct 9 2021, 07:48 PM
bkrantz   And then de-burred. Ready to get back to engine a...   Oct 9 2021, 07:50 PM
bkrantz   Shims in place, under the rocker shaft towers.   Oct 9 2021, 07:51 PM
bkrantz   Ready for new pushrod tubes and seals.   Oct 9 2021, 07:52 PM
bkrantz   Lots of oil on the seals before rolling them onto ...   Oct 9 2021, 07:56 PM
bkrantz   I even remembered the pushrod retaining wires.   Oct 9 2021, 07:57 PM
bkrantz   After lubing the rockers, shafts, spacers, pushrod...   Oct 9 2021, 08:02 PM
bkrantz   I just got started on the other side today, when t...   Oct 10 2021, 08:10 PM
bkrantz   We took a 3 hour hike in the San Juan Mountains, a...   Oct 10 2021, 08:13 PM
Puebloswatcop   We took a 3 hour hike in the San Juan Mountains, ...   Oct 11 2021, 07:57 AM
bkrantz   Left side valve gear in place and quickly adjusted...   Oct 11 2021, 07:23 PM
bkrantz   OK, finally--time to keep going on engine assembly...   Oct 11 2021, 07:25 PM
bkrantz   Pretty valve covers and new gaskets.   Oct 11 2021, 07:25 PM
bkrantz   Valve covers in place--looks more complete!   Oct 11 2021, 07:27 PM
bkrantz   Oil filter mount and new filter. Gotta remember t...   Oct 11 2021, 07:29 PM
iankarr   Oil filter mount and new filter. Gotta remember ...   Oct 11 2021, 08:10 PM
bkrantz   Oil filter mount and new filter. Gotta remember...   Oct 12 2021, 07:34 PM
bkrantz   Then it was time for the oil cooler. I bought a n...   Oct 11 2021, 07:32 PM
bkrantz   A test fit, and interference with the bracket for ...   Oct 11 2021, 07:34 PM
bkrantz   I also found very minor interference with the uppe...   Oct 11 2021, 07:37 PM
bkrantz   Then new cooler seals.   Oct 11 2021, 07:39 PM
bkrantz   New oil cooler mounted, but...   Oct 11 2021, 07:40 PM
bkrantz   The replacement cooler has extended edges on the o...   Oct 11 2021, 07:42 PM
bkrantz   The wall is also aluminum, so pretty easy to trim ...   Oct 11 2021, 07:44 PM
bkrantz   Same on the other side.   Oct 11 2021, 07:44 PM
bkrantz   Good clearance now for the bracket.   Oct 11 2021, 07:46 PM
bkrantz   Next, the engine mount brackets and bushings.   Oct 12 2021, 07:36 PM
bkrantz   Done.   Oct 12 2021, 07:37 PM
bkrantz   Then the thermostat. Here are the old and new par...   Oct 12 2021, 07:39 PM
bkrantz   I installed the pulley and mounting bolt with some...   Oct 12 2021, 07:40 PM
bkrantz   New thermostat. I hope this is not the operating ...   Oct 12 2021, 07:48 PM
bkrantz   And new cable, which looks very suspiciously like ...   Oct 12 2021, 07:50 PM
bkrantz   Assembled on the mounting bracket (another powder-...   Oct 12 2021, 07:52 PM
bkrantz   Installed.   Oct 12 2021, 07:52 PM
bkrantz   Checking the whiteboard--making progress.   Oct 12 2021, 07:53 PM
bkrantz   Next up: the blower housing. I had this lightly b...   Oct 12 2021, 08:03 PM
Cairo94507   I think the epoxy matte clear is the perfect choic...   Oct 13 2021, 06:31 AM
FlacaProductions   Great work here - is that the Awesome Powdercoat t...   Oct 13 2021, 10:24 AM
bkrantz   Thanks, guys. The thermostat bracket is OEM, done...   Oct 13 2021, 07:51 PM
bkrantz   Got to Tucson today, after stopping in Lake Havasu...   Oct 14 2021, 08:57 PM
bkrantz   Complete rebuild for $150.   Oct 14 2021, 08:58 PM
930cabman   Complete rebuild for $150. Good value and ...   Oct 15 2021, 01:50 PM
Puebloswatcop   Thats a very reasonable price and the product look...   Oct 15 2021, 08:08 AM
bkrantz   I like to take advantage of resources in Tucson, s...   Oct 15 2021, 05:51 PM
bkrantz   No work to report today, but I want to celebrate t...   Oct 16 2021, 08:21 PM
bkrantz   First day in the home garage.   Oct 16 2021, 08:22 PM
bkrantz   Interior stripped out.   Oct 16 2021, 08:24 PM
bkrantz   Engine out. Red paint!   Oct 16 2021, 08:25 PM
bkrantz   Right front inner and outer fender gone, front pan...   Oct 16 2021, 08:31 PM
bkrantz   Rear panel off, right rear outer fender off. Test...   Oct 16 2021, 08:36 PM
bkrantz   Rear back together.   Oct 16 2021, 08:37 PM
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