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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   My first support design. I figure something like ...   Jan 28 2023, 07:52 PM
bkrantz   Meanwhile, I got a new oil seal (and spare) for th...   Jan 28 2023, 07:55 PM
bkrantz   I popped out the old seal, and discovered another ...   Jan 28 2023, 07:56 PM
bkrantz   The case seam in the seal recess is not even at th...   Jan 28 2023, 07:57 PM
930cabman   The case seam in the seal recess is not even at t...   Jan 29 2023, 07:48 AM
bkrantz   The case seam in the seal recess is not even at ...   Jan 29 2023, 10:35 PM
bkrantz   About 10 minutes with some 600 grit sand paper.   Jan 28 2023, 07:58 PM
bkrantz   Now the recess is even across the seam.   Jan 28 2023, 07:59 PM
bkrantz   Time to start putting things back together. First...   Jan 29 2023, 10:37 PM
bkrantz   Smooth.   Jan 29 2023, 10:37 PM
bkrantz   Then I got the seal ready to install, with a bit o...   Jan 29 2023, 10:39 PM
bkrantz   Then a couple of dabs of gasket sealant in the sea...   Jan 29 2023, 10:40 PM
bkrantz   Turns out my PVC pipe wheel cap tool is the right ...   Jan 29 2023, 10:41 PM
bkrantz   Seal fully seated and bottomed out against the int...   Jan 29 2023, 10:43 PM
bkrantz   Hub with a bit of grease.   Jan 29 2023, 10:43 PM
bkrantz   Torquing the hub retaining nut to 3.2 m-kg.   Jan 29 2023, 10:47 PM
bkrantz   With a big screwdriver in the flywheel teeth to ho...   Jan 29 2023, 10:48 PM
bkrantz   Next the oil pump cover.   Jan 29 2023, 10:49 PM
bkrantz   A thin smear of sealant on the gasket.   Jan 29 2023, 10:50 PM
bkrantz   Both sides.   Jan 29 2023, 10:51 PM
bkrantz   New sealing nuts.   Jan 29 2023, 10:51 PM
bkrantz   Cover in place and torqued down.   Jan 29 2023, 10:52 PM
bkrantz   New oil filter, truly tightened this time. All se...   Jan 29 2023, 10:53 PM
bkrantz   Engine mount brackets installed.   Jan 29 2023, 10:54 PM
bkrantz   Checking the fit of my dual-oil pressure sensor se...   Jan 29 2023, 10:58 PM
ClayPerrine   Checking the fit of my dual-oil pressure sensor s...   Jan 30 2023, 07:00 AM
bkrantz   Checking the fit of my dual-oil pressure sensor ...   Jan 30 2023, 08:45 PM
cassmcentee   Your pics are so clear, enjoying watching the prog...   Jan 30 2023, 08:50 AM
bkrantz   More fitting and thinking. In this configuration,...   Jan 30 2023, 08:47 PM
windforfun   More fitting and thinking. In this configuration...   Feb 1 2023, 07:43 PM
bkrantz   More fitting and thinking. In this configuratio...   Feb 1 2023, 08:55 PM
bkrantz   Meanwhile, I cleaned up the intake surfaces on the...   Jan 30 2023, 08:49 PM
bkrantz   Question for the 914World experts: how critical to...   Jan 30 2023, 08:51 PM
porschetub   Question for the 914World experts: how critical t...   Feb 1 2023, 12:19 PM
bkrantz   Last thing today: mount the engine cross bar and g...   Jan 30 2023, 08:52 PM
DRPHIL914   Cover in place and torqued down. :beer2: nic...   Feb 1 2023, 01:35 PM
bkrantz   Cover in place and torqued down. :beer2: ni...   Feb 1 2023, 08:53 PM
bkrantz   Can't do much on the engine, since I can't...   Feb 2 2023, 08:29 PM
bkrantz   On to some other tasks. I am still not sure how I...   Feb 2 2023, 08:31 PM
bkrantz   I also pulled the left door handle, since the lock...   Feb 2 2023, 08:33 PM
bkrantz   More tweaking of the cylinder pins!   Feb 2 2023, 08:34 PM
autopro   Sorry to hear of the problems on your oil leaks, I...   Feb 3 2023, 02:14 PM
bkrantz   Sorry to hear of the problems on your oil leaks, ...   Feb 3 2023, 08:15 PM
bkrantz   Final(?) tweak of the left door lock cylinder.   Feb 4 2023, 09:00 PM
bkrantz   Seems to work 99% of the time, with just occasiona...   Feb 4 2023, 09:02 PM
bkrantz   Door lock re-installed. Once I get some duplicate...   Feb 4 2023, 09:03 PM
bkrantz   Time to get my "new" dual oil pressure s...   Feb 5 2023, 10:26 PM
bkrantz   After some test fits, including with copper washer...   Feb 5 2023, 10:28 PM
bkrantz   Here's my thin brass seal washer. That goes o...   Feb 5 2023, 10:29 PM
bkrantz   With some Permatex #1 on all surfaces, I was able ...   Feb 5 2023, 10:31 PM
bkrantz   One more visual check of how the VDO sender will m...   Feb 5 2023, 10:32 PM
bkrantz   Everything looks good, so time to start putting th...   Feb 5 2023, 10:35 PM
bkrantz   And the left front duct.   Feb 5 2023, 10:36 PM
bkrantz   And finished up today with the inner blower housin...   Feb 5 2023, 10:36 PM
bkrantz   Hall sensor tooth gear.   Feb 6 2023, 08:10 PM
bkrantz   Blower cage.   Feb 6 2023, 08:11 PM
bkrantz   Blow-back vent flappers.   Feb 6 2023, 08:12 PM
bkrantz   Alternator.   Feb 6 2023, 08:13 PM
bkrantz   Front blower housing and alternator sheet metal. ...   Feb 6 2023, 08:14 PM
bkrantz   I made a shorter jumper cable for the stock oil pr...   Feb 6 2023, 08:16 PM
bkrantz   Roughly how it fits.   Feb 6 2023, 08:16 PM
bkrantz   Rear sheet metal pieces, left and right.   Feb 6 2023, 08:18 PM
bkrantz   Side sheet metal pieces.   Feb 6 2023, 08:18 PM
bkrantz   Front sheet metal.   Feb 6 2023, 08:19 PM
bkrantz   I attached the thermostat cable to the flap pivot.   Feb 6 2023, 08:20 PM
bkrantz   A little voice told me to test it, so I got out my...   Feb 6 2023, 08:21 PM
bkrantz   The thermostat bellows expanded, but the cable wen...   Feb 6 2023, 08:22 PM
bkrantz   And the flap pivot did not rotate much. I could m...   Feb 6 2023, 08:23 PM
bkrantz   Turns out the plastic bushing on the right side wa...   Feb 6 2023, 08:24 PM
bkrantz   I hit the bellows with the heat gun again, and thi...   Feb 6 2023, 08:25 PM
bkrantz   And the pivot and flaps rotated as specified.   Feb 6 2023, 08:26 PM
bkrantz   With the rear piece, I have all the top sheet meta...   Feb 6 2023, 08:26 PM
bkrantz   Last thing today: the new VDO sensor.   Feb 6 2023, 08:27 PM
bkrantz   A few more bits today. Spark plug wires.   Feb 9 2023, 08:24 PM
bkrantz   J-tubes.   Feb 9 2023, 08:24 PM
bkrantz   I cleaned the old gaskets off the intakes, and it ...   Feb 9 2023, 08:26 PM
bkrantz   More sanding. Getting flatter.   Feb 9 2023, 08:27 PM
bkrantz   Intake manifolds installed (with thin gaskets).   Feb 11 2023, 08:34 PM
bkrantz   Oil filler/breather.   Feb 11 2023, 08:35 PM
bkrantz   Top side wires, including starter cable.   Feb 11 2023, 08:36 PM
bkrantz   Got out my 3M real rubber tape.   Feb 11 2023, 08:37 PM
bkrantz   And made a wrap to insulate the starter terminal.   Feb 11 2023, 08:38 PM
bkrantz   And also sealed the gap between the rear sheet met...   Feb 11 2023, 08:39 PM
bkrantz   Fuel lines and clamps, including brackets for spar...   Feb 11 2023, 08:40 PM
bkrantz   Fuel lines installed.   Feb 11 2023, 08:41 PM
bkrantz   Throttle bodies. I know I can't lift the engi...   Feb 11 2023, 09:02 PM
bkrantz   Like the throttle connection cable (from Tangerine...   Feb 11 2023, 09:04 PM
bkrantz   Installed and adjusted.   Feb 11 2023, 09:05 PM
bkrantz   EFI system vacuum hose.   Feb 11 2023, 09:06 PM
bkrantz   Installed.   Feb 11 2023, 09:06 PM
bkrantz   Ready to go into the car.   Feb 11 2023, 09:07 PM
bkrantz   The parts cart is empty--that's a good sign.   Feb 11 2023, 09:08 PM
bkrantz   And a few more items done. Got my fingers crossed...   Feb 11 2023, 09:10 PM
Cairo94507   I am eagerly awaiting the install, fire-up and dri...   Feb 12 2023, 09:19 AM
bkrantz   I am eagerly awaiting the install, fire-up and dr...   Feb 12 2023, 07:59 PM
bkrantz   Instead of 914 work I spent a couple of hours play...   Feb 12 2023, 08:04 PM
bkrantz   I did have time to confirm some measurements. The...   Feb 12 2023, 08:06 PM
bkrantz   But the clearance between the rear suspension moun...   Feb 12 2023, 08:07 PM
Puebloswatcop   Fingers Crossed that everything goes well   Feb 13 2023, 05:49 PM
bkrantz   Fingers Crossed that everything goes well Thank...   Feb 13 2023, 09:13 PM
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