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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   Left headlight box.   Apr 18 2020, 08:49 PM
bkrantz   Detail:   Apr 18 2020, 08:50 PM
bkrantz   Right headlight box:   Apr 18 2020, 08:51 PM
bkrantz   More ugly details:   Apr 18 2020, 08:53 PM
bkrantz   Time for surgical removal. I am trying to minimiz...   Apr 18 2020, 08:54 PM
bkrantz   More:   Apr 18 2020, 08:55 PM
bkrantz   And more:   Apr 18 2020, 08:56 PM
bkrantz   The biggest section I removed was the inner side o...   Apr 18 2020, 08:58 PM
bkrantz   Today, the hero tool was the Dremel. We will see ...   Apr 18 2020, 09:00 PM
bkrantz   I started piecing the channel back together today,...   Apr 19 2020, 08:30 PM
bkrantz   The piece cut for the front left corner.   Apr 19 2020, 08:32 PM
bkrantz   I managed to get a bit of curvature, to match the ...   Apr 19 2020, 08:33 PM
bkrantz   Fit in place.   Apr 19 2020, 08:34 PM
bkrantz   And welded in. I had pretty good luck with the th...   Apr 19 2020, 08:36 PM
bkrantz   Right front corner piece.   Apr 19 2020, 08:37 PM
bkrantz   In place.   Apr 19 2020, 08:37 PM
bkrantz   I started to tack weld this, and...the wire ran ou...   Apr 19 2020, 08:39 PM
bkrantz   Back to welding. I can grind these first corner p...   Apr 19 2020, 08:40 PM
Baker17   Your work is inspiring and will be a reference whe...   Apr 20 2020, 09:07 PM
bkrantz   My delay in blasting was a combination of poor pla...   Apr 21 2020, 08:53 PM
bkrantz   Back to work, just an hour yesterday and a couple ...   Apr 21 2020, 08:55 PM
bkrantz   Right side:   Apr 21 2020, 08:57 PM
bkrantz   Next piece for the left side.   Apr 21 2020, 08:58 PM
bkrantz   Welded in place.   Apr 21 2020, 08:59 PM
bkrantz   Same piece for the right side.   Apr 21 2020, 09:00 PM
bkrantz   Welded in place.   Apr 21 2020, 09:00 PM
bkrantz   Inner corner piece for the right side.   Apr 21 2020, 09:03 PM
bkrantz   Welded.   Apr 21 2020, 09:03 PM
bkrantz   Last piece for the right side?   Apr 21 2020, 09:04 PM
bkrantz   Welded.   Apr 21 2020, 09:05 PM
bkrantz   Here's the right side, almost done.   Apr 21 2020, 09:06 PM
bkrantz   First, I caught up with grinding the pieces from y...   Apr 22 2020, 07:39 PM
bkrantz   More grinding.   Apr 22 2020, 07:40 PM
bkrantz   And more grinding.   Apr 22 2020, 07:41 PM
bkrantz   The last bit is the inner edge of the channel all ...   Apr 22 2020, 07:44 PM
bkrantz   Got it tacked in place before quitting time.   Apr 22 2020, 07:45 PM
bkrantz   I finished up the frunk channel today. Before fin...   Apr 23 2020, 08:11 PM
bkrantz   Here's the latch welded on. Don't worry, ...   Apr 23 2020, 08:13 PM
bkrantz   After welding the front channel "seam" a...   Apr 23 2020, 08:16 PM
bkrantz   Frunk channel all done, and another item crossed o...   Apr 23 2020, 08:17 PM
bkrantz   With the frunk channel done, I switched to the rea...   Apr 24 2020, 08:33 PM
bkrantz   And after.   Apr 24 2020, 08:34 PM
bkrantz   Some dents and dings, and holes from the PORSCHE r...   Apr 24 2020, 08:36 PM
bkrantz   The reflector panel holes will get welded, and the...   Apr 24 2020, 08:38 PM
bkrantz   For access to the inside of the panel, I removed t...   Apr 24 2020, 08:40 PM
bkrantz   Here's the mounting plate. Pretty lumpy.   Apr 24 2020, 08:41 PM
raynekat   Here's the mounting plate. Pretty lumpy. H...   Apr 24 2020, 09:27 PM
bkrantz   Here's the mounting plate. Pretty lumpy. ...   Apr 25 2020, 08:20 PM
bkrantz   For better access I unbolted the rotisserie rear u...   Apr 25 2020, 08:23 PM
bkrantz   Now I can see the worst spots.   Apr 25 2020, 08:24 PM
bkrantz   And this.   Apr 25 2020, 08:25 PM
bkrantz   I propped the trunk lid in place, to compare align...   Apr 25 2020, 08:27 PM
bkrantz   Right side looks pretty good.   Apr 25 2020, 08:28 PM
bkrantz   Left side not so great. The problem is mostly a ...   Apr 25 2020, 08:29 PM
bkrantz   I worked more today to get things "straight...   Apr 26 2020, 08:58 PM
bkrantz   Eye-balling along the lower edge of the boss. Ig...   Apr 26 2020, 08:59 PM
bkrantz   Watching the angles.   Apr 26 2020, 09:00 PM
bkrantz   When things where looking nearly straight by eye, ...   Apr 26 2020, 09:02 PM
bkrantz   But the trunk lid has its own problems, especially...   Apr 26 2020, 09:04 PM
bkrantz   As I started to work the trunk lid edge, I heard a...   Apr 26 2020, 09:06 PM
bkrantz   Anyway, I kept working the lid edge and got things...   Apr 26 2020, 09:07 PM
raynekat   Great pic here Bob. Well...spend a bit more time t...   Apr 26 2020, 09:59 PM
bkrantz   Looks good enough for a 10 foot car, but I want be...   Apr 26 2020, 09:08 PM
bkrantz   Great pic here Bob. Well...spend a bit more time ...   Apr 27 2020, 08:18 PM
bkrantz   I decided to take a break from the rear, and work ...   Apr 27 2020, 08:22 PM
bkrantz   Next, I welded all the puller holes from the PO re...   Apr 27 2020, 08:24 PM
bbrock   Next, I welded all the puller holes from the PO r...   Apr 27 2020, 08:29 PM
bkrantz   After grinding the welds, I got the fender shape a...   Apr 27 2020, 08:30 PM
bkrantz   To get the next 5% I am going beyond where I stopp...   Apr 28 2020, 08:16 PM
bkrantz   Take the curve from here...   Apr 28 2020, 08:17 PM
bkrantz   And use it to judge the work here. Gaps still nee...   Apr 28 2020, 08:18 PM
bkrantz   Getting closer to 95%.   Apr 28 2020, 08:19 PM
bkrantz   And after some additional work by eye and feel. I...   Apr 28 2020, 08:20 PM
bkrantz   But meanwhile, plugging the wart holes on the righ...   Apr 28 2020, 08:21 PM
bkrantz   This fender also needs some shaping, especially al...   Apr 28 2020, 08:22 PM
bkrantz   Working through the welding list.   Apr 28 2020, 08:23 PM
bkrantz   And getting started on the shaping list.   Apr 28 2020, 08:24 PM
raynekat   This man knows no fear.....go get 'em Bob.   Apr 28 2020, 08:45 PM
bkrantz   This man knows no fear.....go get 'em Bob. ...   Apr 29 2020, 07:44 PM
bkrantz   I only had about 30 minutes in the garage today. ...   Apr 29 2020, 07:47 PM
bkrantz   Got to use the magic tool again today (shrinking d...   Apr 30 2020, 08:22 PM
bkrantz   Then I got on to shaping, and things are close to ...   Apr 30 2020, 08:22 PM
aggiezig   Just dropping in to admire your progress. You have...   May 1 2020, 12:23 AM
bkrantz   Thanks--just learning as I go. My secret weapon i...   May 1 2020, 08:51 PM
bkrantz   On the the next phase, trying to get the fender as...   May 1 2020, 08:53 PM
bkrantz   That provides a uniform matte black coat. The sur...   May 1 2020, 08:55 PM
bkrantz   Then a a light sanding, to reveal the highs and lo...   May 1 2020, 08:57 PM
bkrantz   I also got started on the right rear fender, layin...   May 1 2020, 08:59 PM
bkrantz   Here are the some lines on the left side to use as...   May 1 2020, 09:00 PM
bkrantz   Had a fun visit by a local 914 friend today, who b...   May 2 2020, 09:09 PM
Kansas 914   Had a fun visit by a local 914 friend today, who ...   May 3 2020, 08:19 AM
bkrantz   Of course, that means re-grinding, re-shaping, and...   May 2 2020, 09:11 PM
BeatNavy   If it's not too much trouble at some point can...   May 3 2020, 06:27 AM
bkrantz   Just for you, Rob, I took some photos of my proced...   May 4 2020, 08:18 PM
bkrantz   Step 2: press against the fender, holding the gaug...   May 4 2020, 08:19 PM
bkrantz   Step 3: Now hold the gauge (gently) along the same...   May 4 2020, 08:21 PM
bkrantz   Step 4: repeat the process along all the lines. I...   May 4 2020, 08:22 PM
bkrantz   After about an hour, I got the right fender profil...   May 4 2020, 08:23 PM
bkrantz   I then went back to the front fenders, trying to l...   May 4 2020, 08:25 PM
bkrantz   And the right side.   May 4 2020, 08:25 PM
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