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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   New fuzzy channel for the window guide.   Nov 8 2021, 07:53 PM
bkrantz   Installed.   Nov 8 2021, 07:54 PM
bkrantz   Now the fun part: trying to get the seal seated in...   Nov 8 2021, 07:56 PM
bkrantz   After lots of struggle, I could not get the front ...   Nov 8 2021, 07:57 PM
bkrantz   And the outer part of the seal will not seat horiz...   Nov 8 2021, 07:59 PM
bkrantz   And worst of all, I split the outer seal above the...   Nov 8 2021, 08:01 PM
iankarr   Definitely tricky business. Mark at 914rubber prov...   Nov 8 2021, 08:32 PM
bkrantz   Thanks, Ian. I tried a few times with different a...   Nov 9 2021, 08:04 PM
raynekat   Bob....I must have tried installing this triangle ...   Nov 10 2021, 03:06 AM
bkrantz   You are right, Doug. If there is any general cate...   Nov 10 2021, 09:01 PM
bkrantz   Yup, doors (at least right door), going on the car...   Nov 10 2021, 09:05 PM
bkrantz   Tidy fit with no slop.   Nov 10 2021, 09:05 PM
bkrantz   Quick adjustment of hinge positions and latch look...   Nov 10 2021, 09:07 PM
bkrantz   Meanwhile, back to the engine. Here is the new (u...   Nov 10 2021, 09:12 PM
bkrantz   The hardware furthers my quest to replace all the ...   Nov 10 2021, 09:14 PM
TX914   The hardware furthers my quest to replace all the...   Nov 11 2021, 06:19 AM
bkrantz   The hardware furthers my quest to replace all th...   Nov 11 2021, 08:28 PM
bkrantz   I pulled all the sheet metal off the front, just s...   Nov 10 2021, 09:16 PM
bkrantz   Alternator ring in place.   Nov 10 2021, 09:17 PM
bkrantz   With all the sheet metal back in place, it was tim...   Nov 10 2021, 09:18 PM
bkrantz   Just a bit of tension, and ready.   Nov 10 2021, 09:20 PM
Puebloswatcop   Beautiful work Bob.   Nov 11 2021, 02:30 PM
bkrantz   I took the left door off to get that side started.   Nov 11 2021, 08:30 PM
bkrantz   Locks and levers in place, and working.   Nov 11 2021, 08:31 PM
bkrantz   I need a few bits to finish the door, so instead I...   Nov 11 2021, 08:33 PM
bkrantz   First, I made a trial assembly of the brackets and...   Nov 12 2021, 08:22 PM
bkrantz   Close-up of the brackets. The fit and machine wor...   Nov 12 2021, 08:23 PM
bkrantz   The Tangerine kit includes longer manifold studs, ...   Nov 12 2021, 08:27 PM
bkrantz   The longer studs go on the insides of the manifold...   Nov 12 2021, 08:29 PM
bkrantz   Check fit with the left throttle body and bracket.   Nov 12 2021, 08:30 PM
bkrantz   Now for some fun! Here is the right throttle ...   Nov 12 2021, 08:32 PM
bkrantz   Lever arm and washers removed, and the throttle st...   Nov 12 2021, 08:34 PM
bkrantz   Here's the recommended pulley position. I pla...   Nov 12 2021, 08:37 PM
bkrantz   The small dimple is the pin location, marked with ...   Nov 12 2021, 08:42 PM
bkrantz   So I moved the hole position slightly to the left.   Nov 12 2021, 08:43 PM
bkrantz   I then chamfered the hole so the split pin can sli...   Nov 12 2021, 08:43 PM
bkrantz   Here's the throttle stop back on the shaft, wi...   Nov 12 2021, 08:44 PM
bkrantz   Using the press to install the split pin in the pu...   Nov 12 2021, 08:45 PM
bkrantz   I pushed the split pin through the pulley just far...   Nov 12 2021, 08:47 PM
bkrantz   New return spring on the back side of the pulley.   Nov 12 2021, 08:48 PM
bkrantz   Pulley in place, but I need a couple of washers (M...   Nov 12 2021, 08:50 PM
bkrantz   Still waiting on washers, so I started on my left ...   Nov 15 2021, 08:44 PM
bkrantz   Throttle stop marked for pin.   Nov 15 2021, 08:45 PM
bkrantz   Again, the pin position was too close to the edge,...   Nov 15 2021, 08:46 PM
bkrantz   Hole drilled and chamfered.   Nov 15 2021, 08:47 PM
bkrantz   Split pin pressed into slave pulley, again just en...   Nov 15 2021, 08:49 PM
bkrantz   Getting closer to mounting everything on the engin...   Nov 15 2021, 08:49 PM
bkrantz   One thing I did get is a replacement door stay spr...   Nov 15 2021, 08:51 PM
bkrantz   Door stay ready.   Nov 15 2021, 08:52 PM
bkrantz   Some light lube, and then installed.   Nov 15 2021, 08:53 PM
bkrantz   I then hung the door, and made a first alignment o...   Nov 15 2021, 08:54 PM
bkrantz   Rear gap better. I will work on this more later o...   Nov 15 2021, 08:55 PM
bkrantz   With the door mounted, I installed the window wind...   Nov 15 2021, 08:56 PM
bkrantz   With both doors on, I could not resist some glamou...   Nov 15 2021, 08:57 PM
bkrantz   One more.   Nov 15 2021, 08:58 PM
raynekat   Perhaps plexiglass hoods? Then you'd know what...   Nov 15 2021, 10:25 PM
bkrantz   Perhaps plexiglass hoods? Then you'd know wha...   Nov 16 2021, 08:12 PM
Puebloswatcop   Looking awesome Bob, :driving:   Nov 16 2021, 07:40 AM
bkrantz   Got my M7 washers, just the size for the throttle ...   Nov 17 2021, 07:58 PM
bkrantz   Slave pulley mount test. Two washes do the job.   Nov 17 2021, 07:59 PM
bkrantz   Here's the slave pulley, set up with the mount...   Nov 17 2021, 08:01 PM
bkrantz   All together on the left throttle body.   Nov 17 2021, 08:02 PM
bkrantz   Then I got the cable stop aligned with the pulley.   Nov 17 2021, 08:04 PM
bkrantz   I also swapped out the bottom plates for the air f...   Nov 17 2021, 08:08 PM
bkrantz   Right side with the master pulley.   Nov 17 2021, 08:10 PM
bkrantz   Again, I lined up the cable stops with the pulley.   Nov 17 2021, 08:11 PM
bkrantz   Now its time for the auxiliary cable that connects...   Nov 17 2021, 08:12 PM
bkrantz   Obvious route for the cable, from right to left.   Nov 17 2021, 08:13 PM
bkrantz   But this leaves the middle hanging unsupported, wh...   Nov 17 2021, 08:16 PM
bkrantz   So I made a small bracket to support the middle of...   Nov 17 2021, 08:17 PM
bkrantz   As a straight line, the cable housing is about an ...   Nov 17 2021, 08:19 PM
bkrantz   Time to get out the bike tools again, this time a ...   Nov 17 2021, 08:20 PM
bkrantz   That leaves the housing end a bit jagged.   Nov 17 2021, 08:21 PM
bkrantz   Filed flat, so the cable housing sits even in the ...   Nov 17 2021, 08:22 PM
bkrantz   Cable housing installed.   Nov 17 2021, 08:23 PM
bkrantz   Cross cable end on the master pulley.   Nov 17 2021, 08:24 PM
bkrantz   And on the slave side. I made a preliminary tensi...   Nov 17 2021, 08:25 PM
bkrantz   Once the engine is installed, I will connect the t...   Nov 17 2021, 08:43 PM
bkrantz   In order to reach the right rear, the accelerator ...   Nov 17 2021, 08:47 PM
bkrantz   Rubber grommet.   Nov 17 2021, 08:47 PM
bkrantz   Should work.   Nov 17 2021, 08:48 PM
bkrantz   I got out the new coil, to explore location and mo...   Nov 17 2021, 08:49 PM
bkrantz   My first idea is to mount it on top of the engine ...   Nov 17 2021, 08:51 PM
ClayPerrine   My first idea is to mount it on top of the engine...   Nov 18 2021, 09:51 AM
bkrantz   Clay, do you have a photo of one?   Nov 18 2021, 09:51 PM
bkrantz   I laid out the pattern on some 10 gauge aluminum.   Nov 19 2021, 07:50 PM
bkrantz   Cut and bent.   Nov 19 2021, 07:50 PM
bkrantz   Ready to mount the new coil.   Nov 19 2021, 07:51 PM
bkrantz   This should work, but I need some longer case bolt...   Nov 19 2021, 07:52 PM
bkrantz   The engine is just about dressed.   Nov 19 2021, 07:53 PM
Morph914   Great work! This is going to be one very clean...   Nov 20 2021, 06:44 PM
bkrantz   Great work! This is going to be one very clea...   Nov 20 2021, 08:39 PM
bkrantz   Another neglected detail: the wire for the oil tem...   Nov 20 2021, 08:41 PM
bkrantz   My new wire (green, with a hand-drawn black stripe...   Nov 20 2021, 08:41 PM
bkrantz   Through the grommet in the taco plate cover.   Nov 20 2021, 08:43 PM
bkrantz   New crush washers and a dab of gasket sealant.   Nov 20 2021, 08:44 PM
bkrantz   Cover plate installed, and wire crimped in the hol...   Nov 20 2021, 08:45 PM
bkrantz   Next job: new plug wires. This is the MSD kit tha...   Nov 20 2021, 08:47 PM
bkrantz   Plug wires laid out, from spark plugs to the new c...   Nov 20 2021, 08:48 PM
bkrantz   Now to cut each wire to length.   Nov 20 2021, 08:49 PM
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