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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   Here's the filter and some oil from the initia...   Jan 4 2022, 09:10 PM
bkrantz   Time for some more holes! This hole in the ri...   Jan 4 2022, 09:13 PM
bkrantz   And this hole is for the intake vacuum line.   Jan 4 2022, 09:15 PM
bkrantz   And of course I need to paint the new raw edges.   Jan 4 2022, 09:16 PM
bkrantz   Holes painted and time for grommets.   Jan 5 2022, 08:03 PM
bkrantz   Hole ready for the vacuum tube.   Jan 5 2022, 08:04 PM
bkrantz   Vacuum line connected.   Jan 5 2022, 08:04 PM
bkrantz   O2 sensor cable fed from below.   Jan 5 2022, 08:07 PM
bkrantz   Have I mentioned that my speed cable is about 1.5 ...   Jan 5 2022, 08:09 PM
bkrantz   Just about ready to start trimming cable lengths a...   Jan 5 2022, 08:11 PM
bkrantz   Before I forget, I refilled the crankcase. More b...   Jan 5 2022, 08:13 PM
bkrantz   Plus more zinc additive.   Jan 5 2022, 08:13 PM
bkrantz   More progress on the last checklist.   Jan 5 2022, 08:14 PM
bkrantz   Next task: the speedometer cable. When I installe...   Jan 6 2022, 09:31 PM
bkrantz   Once I removed the pedal board and pulled the carp...   Jan 6 2022, 09:33 PM
bkrantz   Now, another problem. The cable retaining nut doe...   Jan 6 2022, 09:35 PM
bkrantz   I spent almost an hour on this. First I chased th...   Jan 6 2022, 09:38 PM
Morph914   I spent almost an hour on this. First I chased t...   Jan 7 2022, 09:57 AM
Puebloswatcop   I spent almost an hour on this. First I chased t...   Jan 7 2022, 06:56 PM
bkrantz   I spent almost an hour on this. First I chased ...   Jan 7 2022, 08:26 PM
bkrantz   With the speedo cable attached, I bundled it with ...   Jan 6 2022, 09:41 PM
bkrantz   Inside buttoned-up.   Jan 6 2022, 09:42 PM
bkrantz   Another item off the last(?) list.   Jan 6 2022, 09:43 PM
Montreal914   Beautiful work and meticulous installation :troph...   Jan 6 2022, 09:43 PM
ndfrigi   wow! been watching your build and give us enco...   Jan 7 2022, 10:46 AM
bkrantz   wow! been watching your build and give us enc...   Jan 7 2022, 08:25 PM
bkrantz   With a few more parts, I am ready to start the ...   Jan 7 2022, 08:29 PM
bkrantz   I decided on this layout, L to R: the tach signal ...   Jan 7 2022, 08:31 PM
bkrantz   Now its just one wire at a time, after confirming ...   Jan 7 2022, 08:33 PM
bkrantz   And first connection on the ground bus.   Jan 7 2022, 08:33 PM
bkrantz   I added some electrical tape along the exposed edg...   Jan 7 2022, 08:37 PM
bkrantz   That's enough for today, with the connections ...   Jan 7 2022, 08:40 PM
bkrantz   Just a few more wires run today. The device on th...   Jan 8 2022, 08:04 PM
bkrantz   Tach signal converter all wired up.   Jan 9 2022, 07:40 PM
bkrantz   So that's all the various boxes and components...   Jan 9 2022, 07:42 PM
bkrantz   Whew. After a solid 5 hours, everything is connec...   Jan 9 2022, 07:44 PM
bkrantz   And here's the waste from shortening the cable...   Jan 9 2022, 07:46 PM
bkrantz   Another task crossed off.   Jan 9 2022, 07:47 PM
bkrantz   One last wire had to be resolved, and the Dub Shop...   Jan 10 2022, 08:36 PM
bkrantz   With everything connections, I turned the key to R...   Jan 10 2022, 08:40 PM
bkrantz   After about 10 spurts of running the starter motor...   Jan 10 2022, 08:43 PM
bkrantz   Because of the mix-up with the Hall sensor wires, ...   Jan 10 2022, 08:47 PM
bkrantz   I also added a mark on the flywheel, 180° opposit...   Jan 10 2022, 08:49 PM
bkrantz   One more thing before starting the engine again: i...   Jan 10 2022, 09:01 PM
bkrantz   Mounting studs.   Jan 10 2022, 09:02 PM
bkrantz   Air filter.   Jan 10 2022, 09:03 PM
bkrantz   And top cover. I still need to decorate that blan...   Jan 10 2022, 09:04 PM
Puebloswatcop   And top cover. I still need to decorate that bla...   Jan 11 2022, 08:24 AM
jesse7flying   Looking great! Would you mind showing a bette...   Jan 11 2022, 09:39 AM
bkrantz   Hi, Jesse. Here is a top view.   Jan 11 2022, 08:28 PM
bkrantz   New hole in the front sheet metal for the accelera...   Jan 11 2022, 08:29 PM
bkrantz   Master pulley on the left.   Jan 11 2022, 08:30 PM
bkrantz   Another view of the left side.   Jan 11 2022, 08:30 PM
bkrantz   Slave pulley on the right.   Jan 11 2022, 08:31 PM
bkrantz   Well, today was a kinda 3 steps backwards day. I c...   Jan 11 2022, 08:43 PM
iankarr   Well, today was a kinda 3 steps backwards day. I ...   Jan 12 2022, 10:24 AM
jesse7flying   Perfect on the pics. Much appreciated, thx Jesse   Jan 12 2022, 09:13 AM
bkrantz   Still sorting out the EFI problems, and then I dec...   Jan 12 2022, 09:23 PM
bkrantz   But the vertical side of the clamp is very tall--t...   Jan 12 2022, 09:25 PM
bkrantz   So I trimmed about 3mm from the lower edge, and th...   Jan 12 2022, 09:26 PM
bkrantz   That extra thickness pushes the clamp closer to th...   Jan 12 2022, 09:27 PM
bkrantz   Now I am waiting for a replacement EFI part before...   Jan 13 2022, 08:26 PM
bkrantz   One more item done.   Jan 13 2022, 08:28 PM
Puebloswatcop   Good Morning Bob, looks like your list is getting ...   Jan 14 2022, 08:56 AM
930cabman   Good Morning Bob, looks like your list is getting...   Jan 14 2022, 06:10 PM
bkrantz   Good Morning Bob, looks like your list is gettin...   Jan 14 2022, 08:31 PM
bkrantz   Good Morning Bob, looks like your list is getting...   Jan 14 2022, 08:29 PM
bkrantz   I have most of the parts to hook up the heating sy...   Jan 14 2022, 08:35 PM
bkrantz   I also have some new bits from 914Rubber, includin...   Jan 14 2022, 08:43 PM
bkrantz   First section of duct (passenger side).   Jan 14 2022, 08:45 PM
bkrantz   And the section section, up through the sheet meta...   Jan 14 2022, 08:48 PM
bkrantz   The the fun started, with the short section that c...   Jan 14 2022, 08:53 PM
bkrantz   The duct section is round.   Jan 14 2022, 08:54 PM
bkrantz   But the outlet on the SS heat exchangers is not...   Jan 14 2022, 08:55 PM
bkrantz   Since the ducts are loose, I tried reforming the s...   Jan 14 2022, 08:56 PM
bkrantz   Next, I had a pair of cuts to help shrink the end ...   Jan 14 2022, 08:57 PM
bkrantz   Two more pairs of cuts finally did the trick, and ...   Jan 14 2022, 08:58 PM
bkrantz   The upper hole on the outlet also needed some adju...   Jan 14 2022, 08:59 PM
bkrantz   Finally! Duct in place, with bolts top and bo...   Jan 14 2022, 09:00 PM
bkrantz   Last bit today. I got the right side control box i...   Jan 14 2022, 09:10 PM
bkrantz   Now the left side. First I modified the horizonta...   Jan 15 2022, 08:29 PM
bkrantz   Flap valve modified by rounding the lower corners.   Jan 15 2022, 08:31 PM
bkrantz   Ducts from the blower housing to the exchanger, an...   Jan 15 2022, 08:32 PM
bkrantz   Upper hole elongated, just like the right side.   Jan 15 2022, 08:33 PM
bkrantz   Horizontal duct forced into place. Now I just nee...   Jan 15 2022, 08:34 PM
bkrantz   Yesterday, the postman delivered another NOS heat ...   Jan 16 2022, 09:27 PM
bkrantz   In case I was not sure which side?   Jan 16 2022, 09:28 PM
bkrantz   So that's where I put it. Upside down?   Jan 16 2022, 09:28 PM
bkrantz   I need a few more little parts to finish the heat ...   Jan 16 2022, 09:33 PM
bkrantz   It fits just right, with a dab of aviation sealant...   Jan 16 2022, 09:34 PM
bkrantz   Breather re-installed and the vent hoses all conne...   Jan 16 2022, 09:35 PM
bkrantz   With a bit more time to play, I got down the rear ...   Jan 16 2022, 09:38 PM
bkrantz   If you recall from 2 years ago, I had to weld in a...   Jan 16 2022, 09:41 PM
bkrantz   To install the valence I removed the bumper. No b...   Jan 16 2022, 09:42 PM
bkrantz   On both license plate lights, the ground wire term...   Jan 16 2022, 09:47 PM
bkrantz   I did get the valence mounted, with a little bit o...   Jan 16 2022, 09:50 PM
bkrantz   Clearance to the tail pipe is a bit less than 1/4 ...   Jan 16 2022, 09:51 PM
bkrantz   I replaced the ground wire terminals, and stripped...   Jan 17 2022, 07:55 PM
bkrantz   With the bumper back on the rear end is complete.   Jan 17 2022, 07:56 PM
bkrantz   I finally got my replacement for the throttle posi...   Jan 17 2022, 08:02 PM
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