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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   And I took a quick look at the rear panel. More w...   May 4 2020, 08:26 PM
BeatNavy   Ok, that helps fill in the gap, thank you! I...   May 5 2020, 04:42 AM
bkrantz   Never enough tools! https://www.amazon.com/gp...   May 5 2020, 09:42 PM
bkrantz   First job today was to weld up the "extra...   May 6 2020, 08:00 PM
bkrantz   I then gave the other panels another smoothing pas...   May 6 2020, 08:03 PM
bkrantz   Front right   May 6 2020, 08:03 PM
bkrantz   Left cowl   May 6 2020, 08:04 PM
bkrantz   Right cowl   May 6 2020, 08:04 PM
bkrantz   And I made a first check of the right rear fender....   May 6 2020, 08:06 PM
bkrantz   I took a break from panel work today. The first t...   May 7 2020, 08:20 PM
bkrantz   First step was to cut off the remains bit of stud,...   May 7 2020, 08:22 PM
bkrantz   Then I tapped the new hole (M8 x 1.0).   May 7 2020, 08:22 PM
bkrantz   Here's the new stud screwed in place.   May 7 2020, 08:23 PM
bkrantz   And then tack-welded (along with the PO hole) and ...   May 7 2020, 08:24 PM
bkrantz   Next, I went to work on the trunk lid. As I previ...   May 7 2020, 08:26 PM
bkrantz   Today, I went after more of the foam. I managed t...   May 7 2020, 08:28 PM
bkrantz   I broke out the bore scope to see the degree of ru...   May 7 2020, 08:29 PM
bkrantz   Here's a shot from inside the space between th...   May 7 2020, 08:31 PM
raynekat   Here's a shot from inside the space between t...   May 7 2020, 10:06 PM
Kansas 914   I wonder if there is a chemical that would "e...   May 8 2020, 08:32 AM
bbrock   I wonder if there is a chemical that would ...   May 8 2020, 10:40 AM
BeatNavy   Is that the same foam used in the body above tail ...   May 8 2020, 03:50 PM
bkrantz   Not sure. The foam in the trunk lid rib is yellow...   May 8 2020, 08:55 PM
bkrantz   In any case, I made a foam scooping and pulling to...   May 8 2020, 08:57 PM
bkrantz   After a couple of hours:   May 8 2020, 08:58 PM
bkrantz   I got 99% of the foam. And the rust looks minimal...   May 8 2020, 08:58 PM
gereed75   Some brake cleaners may work to dissolve foam, but...   May 9 2020, 04:45 AM
Dion   I don’t know how I missed this thread, maybe the...   May 9 2020, 06:24 AM
bkrantz   Thanks, Dion. Doing the work, and the documentati...   May 9 2020, 08:11 PM
bkrantz   Speaking of foam, has anyone replaced the foam in ...   May 9 2020, 08:12 PM
bkrantz   More work on the trunk lid today. Here's the ...   May 9 2020, 08:13 PM
bkrantz   The patch requires a double curve, one sharper and...   May 9 2020, 08:14 PM
bkrantz   Fit in place.   May 9 2020, 08:15 PM
bkrantz   Tack-welded in place. The thin metal around the e...   May 9 2020, 08:16 PM
bkrantz   And all welded in place. Grinding tomorrow.   May 9 2020, 08:17 PM
bkrantz   I also welded a small crack in the rib along the r...   May 9 2020, 08:18 PM
bkrantz   And I welded two holes in the middle of the trunk ...   May 9 2020, 08:19 PM
bkrantz   Got back to work on the trunk lid today. Grinding...   May 10 2020, 08:11 PM
bkrantz   Grinding down the crack welding in the right side ...   May 10 2020, 08:12 PM
bkrantz   And grinding down the welding around the patch. I...   May 10 2020, 08:13 PM
bkrantz   I then set the trunk lid back on the car, propped ...   May 10 2020, 08:14 PM
bkrantz   The trailing edge has been bent inward. I suspect...   May 10 2020, 08:17 PM
bkrantz   On the left side, the bend is more abrupt. I need...   May 10 2020, 08:18 PM
bkrantz   Meanwhile, I finished up the metal work on the rig...   May 10 2020, 08:21 PM
bkrantz   I worked more on the trunk lid today. First I mad...   May 11 2020, 08:12 PM
bkrantz   After some gentle prying, plus some more hammer wo...   May 11 2020, 08:14 PM
bkrantz   Looks good by eye.   May 11 2020, 08:14 PM
bkrantz   And even better from a few feet away.   May 11 2020, 08:16 PM
jaredmcginness   And even better from a few feet away. Love this...   May 12 2020, 06:15 AM
raynekat   I'd say just slap some paint on that baby Bob....   May 11 2020, 09:01 PM
bkrantz   I'd say just slap some paint on that baby Bob...   May 12 2020, 07:40 PM
bkrantz   More work one the trunk lid today, and playing wit...   May 12 2020, 07:43 PM
bkrantz   Here's a shallow dent in the outer skin, along...   May 12 2020, 07:45 PM
bkrantz   So heat the glue gun, apply to tab, stick on to ce...   May 12 2020, 07:46 PM
bkrantz   Not bad now.   May 12 2020, 07:46 PM
bkrantz   I pulled a few more dents in the outer skin with p...   May 12 2020, 07:49 PM
bkrantz   I then flipped the lid over and went after some de...   May 12 2020, 07:50 PM
bkrantz   But the hot glue is not strong enough and the pull...   May 12 2020, 07:50 PM
bkrantz   I could have done what a PO did, and drill holes f...   May 12 2020, 07:53 PM
bkrantz   Instead I welded on studs that my big slide hammer...   May 12 2020, 07:54 PM
bkrantz   Fist dent came out nicely.   May 12 2020, 07:56 PM
bkrantz   Second dent was going well, and then I pulled too ...   May 12 2020, 07:57 PM
bkrantz   Got the trunk lid done today. I welded up the hol...   May 13 2020, 08:28 PM
bkrantz   I used the same technique to pull the remaining si...   May 13 2020, 08:30 PM
bkrantz   While I had the welder going, I reattached the tru...   May 13 2020, 08:33 PM
bkrantz   Getting close to clearing the list!   May 13 2020, 08:38 PM
bkrantz   On to the next/last bit of significant metal work ...   May 14 2020, 08:41 PM
bkrantz   I am still pondering how I want to do this (fully ...   May 14 2020, 08:43 PM
ElCee   I am still pondering how I want to do this (fully...   May 16 2020, 04:14 AM
jaredmcginness   Hmmm. I need to finish my battery tray and engine...   May 15 2020, 10:05 AM
bkrantz   I am leaning that way, too. I know I will install...   May 15 2020, 09:15 PM
bkrantz   Thanks--very clever solution. I decided to go old...   May 16 2020, 08:54 PM
bkrantz   And weld everything in place. But first I pulled ...   May 16 2020, 08:58 PM
bkrantz   The underside is clean, and never welded.   May 16 2020, 09:00 PM
bkrantz   I used some solvent (3M Adhesive Remover seems to ...   May 16 2020, 09:01 PM
bkrantz   In fact, this piece was only attached by some epox...   May 16 2020, 09:02 PM
bkrantz   I started with the support, with some plug welds i...   May 16 2020, 09:06 PM
bkrantz   And then more plug welds on the side flanges.   May 16 2020, 09:07 PM
bkrantz   Here is the tray clamped in place.   May 16 2020, 09:08 PM
bkrantz   I started with more plug welds from inside the fen...   May 16 2020, 09:09 PM
bkrantz   And then finished up with welding the under side o...   May 16 2020, 09:10 PM
bkrantz   The list is almost done!   May 16 2020, 09:11 PM
Tman914   Nice job by the way it’s looking really nice wor...   May 17 2020, 02:27 PM
bkrantz   Thanks, Tman. No 914 work today, but when I took ...   May 17 2020, 08:52 PM
raynekat   Thanks, Tman. No 914 work today, but when I took...   May 17 2020, 09:03 PM
bkrantz   Thanks, Tman. No 914 work today, but when I too...   May 18 2020, 08:12 PM
bkrantz   I worked on the targa hoop top today, to remove a ...   May 19 2020, 09:12 PM
bkrantz   One more shot of my list.   May 19 2020, 09:13 PM
tygaboy   Your garage door thanks you! :lol:   May 20 2020, 08:21 AM
bkrantz   And I don't have to listen to the squealing gu...   May 20 2020, 08:31 PM
bkrantz   And so on to the last big chore on the body shell:...   May 20 2020, 08:33 PM
bkrantz   Here's a start, inside the front right fender.   May 20 2020, 08:34 PM
Lilchopshop   Bob, I love your thread and use it daily to guide ...   May 21 2020, 08:12 AM
bkrantz   Bob, I love your thread and use it daily to guide...   May 21 2020, 09:32 PM
Kansas 914   The shop does want to use the rotisserie, as well...   May 22 2020, 10:24 AM
bkrantz   Another bit of progress today. This does not look...   May 23 2020, 08:15 PM
bbrock   Simply amazing! That whiteboard is two years ...   May 23 2020, 08:32 PM
bkrantz   Back to the festival of weld grinding. It does ma...   May 24 2020, 07:20 PM
bkrantz   Inside the RR fender.   May 24 2020, 07:20 PM
bkrantz   Along the front panel lower seam.   May 24 2020, 07:21 PM
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