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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 slide the boot on (tight!).   Nov 20 2021, 08:50 PM
bkrantz   Crimp the connector.   Nov 20 2021, 08:51 PM
bkrantz   First wire done.   Nov 20 2021, 08:52 PM
bkrantz   In place. I need to get some plug wire holders.   Nov 20 2021, 08:52 PM
bkrantz   I made up the other 3 plug wires today, and plugge...   Nov 21 2021, 08:27 PM
bkrantz   Next up: Fuel lines and components.   Nov 21 2021, 08:29 PM
bkrantz   This is the pressure regulator, and the Dub Shop b...   Nov 21 2021, 08:30 PM
bkrantz   I don't need the auxiliary ports, so installed...   Nov 21 2021, 08:32 PM
bkrantz   And then the barbed fittings for input (side) and ...   Nov 21 2021, 08:34 PM
bkrantz   I will mount this on the bracket for the original ...   Nov 21 2021, 08:34 PM
bkrantz   Drilled some new holes, and mounted the bracket.   Nov 21 2021, 08:35 PM
bkrantz   And then the regulator.   Nov 21 2021, 08:36 PM
bkrantz   Now time for the fuel lines, starting with new gro...   Nov 21 2021, 08:42 PM
bkrantz   Grommets in place.   Nov 21 2021, 08:42 PM
bkrantz   First, I tried the short hard-lines upside-down, s...   Nov 21 2021, 08:46 PM
bkrantz   The "correct" way looks better.   Nov 21 2021, 08:47 PM
bkrantz   Once upon a time, I had a label on the supply line...   Nov 21 2021, 08:50 PM
bkrantz   That worked, with a subtle but distinct air pressu...   Nov 21 2021, 08:51 PM
bkrantz   I also started to mock up the lines on the engine,...   Nov 21 2021, 08:54 PM
bkrantz   Running fuel lines in the engine compartment, to c...   Nov 22 2021, 07:44 PM
bkrantz   I decided to double-clamp all the connections--pro...   Nov 22 2021, 07:47 PM
bkrantz   At the top side, connecting the pressure regulator...   Nov 22 2021, 07:49 PM
bkrantz   Last bit today: sealing the fittings in the inject...   Nov 22 2021, 07:51 PM
bkrantz   Fittings in place, both sides.   Nov 22 2021, 07:52 PM
Puebloswatcop   Bob, this is such inspirational work. Thanks for ...   Nov 23 2021, 07:13 AM
bkrantz   Thanks. I suppose I can get a soundtrack file if ...   Nov 23 2021, 10:16 PM
jamlip   I have Dub Shop injection and spark kit on my 912 ...   Nov 23 2021, 10:32 PM
bkrantz   I have Dub Shop injection and spark kit on my 912...   Nov 24 2021, 08:44 PM
rgalla9146   I'm slowly going through this thread from the ...   Nov 24 2021, 07:49 AM
iankarr   I'm slowly going through this thread from the...   Nov 24 2021, 09:33 AM
bkrantz   I'm slowly going through this thread from th...   Nov 24 2021, 08:47 PM
bkrantz   I'm slowly going through this thread from the...   Nov 24 2021, 08:45 PM
bkrantz   Any guess what this place is? Hint: not far from ...   Nov 30 2021, 09:33 PM
bkrantz   Here it is from the back. Answer: California Moto...   Nov 30 2021, 09:36 PM
bkrantz   Here's my like-new box, strapped into my son...   Nov 30 2021, 09:38 PM
Puebloswatcop   Awesome!!!! I sure wish Arizona w...   Dec 1 2021, 02:53 PM
bkrantz   Forgot to include a picture of the bridge.   Dec 1 2021, 07:52 PM
bkrantz   Arrived home with the transaxle. I unpacked some ...   Dec 6 2021, 09:24 PM
bkrantz   OK, getting back to work. My first chore was to g...   Dec 7 2021, 08:52 PM
bkrantz   Two floor jacks under the back, lifting on the eng...   Dec 7 2021, 08:53 PM
bkrantz   And my engine jack, aka motorcycle lift, on the su...   Dec 7 2021, 08:54 PM
bkrantz   And then down onto my trusty Esco jack stands. I ...   Dec 7 2021, 08:57 PM
bkrantz   Time to get as much finished on the engine, since ...   Dec 7 2021, 08:58 PM
bkrantz   Plugs checked and gapped, and installed. I took th...   Dec 7 2021, 09:04 PM
bkrantz   I also got rubber boots for the plug connectors.   Dec 7 2021, 09:06 PM
bkrantz   Installed. The holes for the rear plugs are near-...   Dec 7 2021, 09:08 PM
bkrantz   Fuel lines run and clamped, and the throttle bodie...   Dec 7 2021, 09:11 PM
Cairo94507   Can't wait to see this in the car and running....   Dec 8 2021, 07:38 AM
Puebloswatcop   You are almost to "drum roll" time. Can...   Dec 8 2021, 08:42 AM
bkrantz   Thanks, guys. It feels close--but close could be ...   Dec 8 2021, 09:18 PM
bkrantz   I am still sorting out all the new electrical conn...   Dec 8 2021, 09:27 PM
bkrantz   More about my wiring plan. I want to modify the 1...   Dec 8 2021, 09:35 PM
bkrantz   I still need the stock 12-pin cable wires for the ...   Dec 8 2021, 09:36 PM
bkrantz   I removed the original lead on pin 12, which suppl...   Dec 8 2021, 09:42 PM
bkrantz   And I replaced it with a new thicker gauge red wir...   Dec 8 2021, 09:43 PM
bkrantz   I checked all the wires and then replaced the brit...   Dec 8 2021, 09:44 PM
bkrantz   Back-up light switch leads with terminals replaced...   Dec 9 2021, 09:54 PM
bkrantz   The rebuilt engine cable with all terminals replac...   Dec 9 2021, 09:56 PM
bkrantz   That should be all the cables and leads, old and n...   Dec 9 2021, 09:58 PM
bkrantz   Stuff that might help: spark plug wire brackets an...   Dec 9 2021, 10:00 PM
Cairo94507   :popcorn: :beer2:   Dec 10 2021, 09:54 AM
bkrantz   Some more engine details. First, I need to make a...   Dec 10 2021, 08:31 PM
bkrantz   Per Dup Shop design, I notched the base plate.   Dec 10 2021, 08:33 PM
bkrantz   The filter element covers most of the notch. Mayb...   Dec 10 2021, 08:34 PM
bkrantz   Then, I started plumbing the engine vacuum system-...   Dec 10 2021, 08:36 PM
bkrantz   Valve installed in the stock location.   Dec 10 2021, 08:37 PM
bkrantz   Some stock-type 12mm vacuum hose, from Belmetric.   Dec 10 2021, 08:38 PM
bkrantz   Left cylinder head to valve.   Dec 10 2021, 08:39 PM
bkrantz   Right cylinder head to valve.   Dec 10 2021, 08:39 PM
bkrantz   Now for the small vacuum line, to connect the thro...   Dec 10 2021, 08:41 PM
bkrantz   I bolted one spark plug wire holder to each side o...   Dec 10 2021, 08:42 PM
bkrantz   Now starting to think about where to put the contr...   Dec 10 2021, 08:44 PM
Puebloswatcop   Now starting to think about where to put the cont...   Dec 13 2021, 05:54 PM
bkrantz   Now starting to think about where to put the con...   Dec 13 2021, 08:22 PM
bkrantz   Or maybe like this? Suggestions welcome!   Dec 10 2021, 08:44 PM
bkrantz   More details on the engine while it is still on th...   Dec 11 2021, 09:08 PM
bkrantz   Speaking of tools, in the back of my ratchet-socke...   Dec 11 2021, 09:11 PM
bkrantz   Holes drilled and tapped.   Dec 11 2021, 09:12 PM
bkrantz   Fittings installed with sealant.   Dec 11 2021, 09:13 PM
bkrantz   No interference with the filter element.   Dec 11 2021, 09:14 PM
bkrantz   Mounted on the left throttle body.   Dec 11 2021, 09:15 PM
bkrantz   Vacuum/vent line from the cylinder heads via the a...   Dec 11 2021, 09:16 PM
bkrantz   I found that the notches in the plug wire brackets...   Dec 11 2021, 09:18 PM
bkrantz   I stacked the plug wire brackets with a pair of ho...   Dec 11 2021, 09:19 PM
bkrantz   For now, the fuel lines and plug wires are done.   Dec 11 2021, 09:20 PM
bkrantz   Here's my SS muffler from Ben Macfarland. I n...   Dec 12 2021, 07:42 PM
bkrantz   I chose a location as far towards the center as po...   Dec 12 2021, 07:43 PM
bkrantz   Ready for welding.   Dec 12 2021, 07:45 PM
bkrantz   I then started the transfer of the engine from the...   Dec 12 2021, 07:48 PM
bkrantz   Bolted onto engine rubber mounts.   Dec 12 2021, 07:49 PM
bkrantz   Here's part one of my two step process. Given...   Dec 12 2021, 07:51 PM
bkrantz   After removing the stand, I lowered the engine so ...   Dec 12 2021, 07:55 PM
bkrantz   With the weight on the jack again, I added an angl...   Dec 12 2021, 07:58 PM
bkrantz   I will leave the jack in place as backup, until th...   Dec 12 2021, 08:00 PM
bkrantz   Last task today: unbolt the engine stand mount fro...   Dec 12 2021, 08:01 PM
nivekdodge   Last task today: unbolt the engine stand mount fr...   Dec 12 2021, 08:29 PM
bkrantz   Last task today: unbolt the engine stand mount f...   Dec 13 2021, 08:10 PM
bkrantz   Everything (almost) I need to get the trans ready ...   Dec 13 2021, 08:26 PM
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