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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   Time for one more step: get the back end hoisted u...   Feb 13 2023, 09:15 PM
bkrantz   OK, progress today! Step 1: get the engine of...   Feb 15 2023, 08:27 PM
bkrantz   Step 2: Lowered down to maneuver.   Feb 15 2023, 08:28 PM
bkrantz   Step 3: roll into place under the car. Plenty of ...   Feb 15 2023, 08:29 PM
bkrantz   Step 4: begin lifting. But not enough side cleara...   Feb 15 2023, 08:32 PM
bkrantz   Step 5: unbolt the ITBs.   Feb 15 2023, 08:32 PM
bkrantz   My solution to get another 2 inches of lift from m...   Feb 15 2023, 08:34 PM
bkrantz   Step 6: get the car back to horizontal.   Feb 15 2023, 08:35 PM
bkrantz   Engine-trans mounting hardware.   Feb 15 2023, 08:36 PM
bkrantz   Coming up--check from the top side.   Feb 15 2023, 08:37 PM
bkrantz   Some cardboard for...   Feb 15 2023, 08:37 PM
bkrantz   Protecting the side sheet metal from the suspensio...   Feb 15 2023, 08:38 PM
bkrantz   Step 7: bolt the engine and trans in place. Yay, ...   Feb 15 2023, 08:39 PM
bkrantz   A good chance to connect the fuel lines, before bo...   Feb 15 2023, 08:41 PM
bkrantz   ITBs back in place, with all fuel lines connected.   Feb 15 2023, 08:43 PM
bkrantz   Now just hook up all the cables and bits, and off ...   Feb 15 2023, 08:43 PM
Puebloswatcop   Fingers crossed Bob. Glad to see it go back toget...   Feb 15 2023, 10:14 PM
bkrantz   Fingers crossed Bob. Glad to see it go back toge...   Feb 16 2023, 10:05 PM
bkrantz   Speaking of work covers, here's what I'm t...   Feb 18 2023, 08:20 PM
bkrantz   I figure one wide piece across the trunk and hangi...   Feb 18 2023, 08:22 PM
930cabman   McMaster Carr?   Feb 19 2023, 05:31 PM
bkrantz   No, the vendor I found is Madison Speaker Componen...   Feb 19 2023, 08:07 PM
bkrantz   Back under the car today. First, I connected the ...   Feb 20 2023, 08:50 PM
bkrantz   Then the shift rod, starting with the front coupli...   Feb 20 2023, 08:52 PM
bkrantz   Then the rear.   Feb 20 2023, 08:54 PM
bkrantz   The back cover is easy, and I was able to re-use t...   Feb 20 2023, 08:57 PM
bkrantz   But I hate the front rubber cover. It took me 20 ...   Feb 20 2023, 08:58 PM
bkrantz   I decided to make a checklist for the engine insta...   Feb 20 2023, 09:01 PM
bkrantz   Here's the first version of my work cover. To...   Feb 21 2023, 09:26 PM
bkrantz   Plus a couple of magnets. (I decided to get some ...   Feb 21 2023, 09:27 PM
bkrantz   Taped to the front corners.   Feb 21 2023, 09:28 PM
bkrantz   Magnets stick to the sails on vinyl.   Feb 21 2023, 09:29 PM
bkrantz   I think this could work.   Feb 21 2023, 09:29 PM
bkrantz   View on the inside. The edge tucks under the tors...   Feb 21 2023, 09:30 PM
bkrantz   I tested the cover with some work on the engine to...   Feb 21 2023, 09:33 PM
bkrantz   And I installed the air filter bases and intake ho...   Feb 21 2023, 09:35 PM
bkrantz   Back in town and on the job. I need to connect th...   Mar 2 2023, 08:59 PM
bkrantz   Then time for rubber surround clips. They might l...   Mar 2 2023, 09:01 PM
bkrantz   Here's a clip as initially installed.   Mar 2 2023, 09:02 PM
bkrantz   And then with the special chrome handles removed. ...   Mar 2 2023, 09:05 PM
bkrantz   Then I got out all the CV joint hardware, especial...   Mar 2 2023, 09:07 PM
bkrantz   Gasket installed. The fit is tight, and it was a ...   Mar 2 2023, 09:09 PM
bkrantz   CVs bolted up and torqued.   Mar 2 2023, 09:10 PM
bkrantz   I then worked on making all the EFI cable connecti...   Mar 2 2023, 09:12 PM
nivekdodge   My buddies we'll be quite impressed with my ca...   Mar 2 2023, 09:14 PM
bkrantz   Plus the connections on the relay board. The alte...   Mar 2 2023, 09:14 PM
bkrantz   Relay cover and custom strap.   Mar 2 2023, 09:15 PM
bkrantz   Then the throttle cable   Mar 2 2023, 09:17 PM
bkrantz   Last thing today, connect all the breather hoses.   Mar 2 2023, 09:20 PM
Cairo94507   :popcorn: :beer2:   Mar 3 2023, 08:32 AM
bkrantz   Ready for mounting the exhaust. The copper gasket...   Mar 4 2023, 08:51 PM
bkrantz   Gaskets installed. Pushed in just right, they sta...   Mar 4 2023, 08:52 PM
bkrantz   I got to try my wobble extension.   Mar 4 2023, 08:52 PM
bkrantz   Just enough flex to reach past the exhaust tube.   Mar 4 2023, 08:53 PM
bkrantz   Heat exchangers installed.   Mar 4 2023, 08:54 PM
bkrantz   Muffler time. It did run kinda hot during the dyn...   Mar 4 2023, 08:58 PM
bkrantz   New gaskets.   Mar 4 2023, 08:58 PM
bkrantz   Flanges aligned and bolted--I did have to loosen t...   Mar 4 2023, 09:00 PM
bkrantz   And then the muffler mounting clamps.   Mar 4 2023, 09:01 PM
nivekdodge   And then the muffler mounting clamps. My forehe...   Mar 5 2023, 07:56 PM
bkrantz   Exhaust all done.   Mar 4 2023, 09:02 PM
Dion   Fantastic work Bob. One hellava 914!   Mar 5 2023, 07:38 AM
bkrantz   Fantastic work Bob. One hellava 914! Thanks...   Mar 5 2023, 08:23 PM
bkrantz   OK, hoping today I can wrap up the underside. Get...   Mar 5 2023, 08:25 PM
bkrantz   J tube   Mar 5 2023, 08:26 PM
bkrantz   Mounted on the exchanger. I still prefer Allen he...   Mar 5 2023, 08:27 PM
bkrantz   Fancy duct.   Mar 5 2023, 08:28 PM
bkrantz   Installed.   Mar 5 2023, 08:28 PM
bkrantz   Heat valve.   Mar 5 2023, 08:29 PM
bkrantz   Plus hi-temp hose.   Mar 5 2023, 08:30 PM
bkrantz   And then the new sheet metal I dod not have last y...   Mar 5 2023, 08:31 PM
bkrantz   Installed.   Mar 5 2023, 08:33 PM
bkrantz   Right side.   Mar 5 2023, 08:33 PM
bkrantz   Installed.   Mar 5 2023, 08:34 PM
bkrantz   Then time for the clutch cable. That means gettin...   Mar 5 2023, 08:37 PM
bkrantz   That's done.   Mar 5 2023, 08:38 PM
bkrantz   Then the speedometer cable.   Mar 5 2023, 08:38 PM
bkrantz   Since this cable did not come with a boot, I made ...   Mar 5 2023, 08:39 PM
bkrantz   Then the O2 sensor cable.   Mar 5 2023, 08:41 PM
bkrantz   I bundled all the cables and covered then with the...   Mar 5 2023, 08:42 PM
bkrantz   Last thing: connecting the heater valve control ca...   Mar 5 2023, 08:43 PM
bkrantz   OK, that should be everything underneath. Yay...   Mar 5 2023, 08:44 PM
bkrantz   Checklist check.   Mar 5 2023, 08:45 PM
Van914   Instead of plastic on cables you might want to use...   Mar 6 2023, 06:03 AM
bkrantz   Instead of plastic on cables you might want to us...   Mar 6 2023, 09:26 PM
bkrantz   I found the heat sleeve, and a metal zip tie.   Mar 9 2023, 08:35 PM
bkrantz   Time to get my new oil pressure sender and gauge w...   Mar 9 2023, 08:37 PM
bkrantz   Back into crimp and heat-shrink mode.   Mar 9 2023, 08:38 PM
bkrantz   Sender end is done.   Mar 9 2023, 08:39 PM
bkrantz   The other end is more complicated.   Mar 9 2023, 08:40 PM
bkrantz   First of all, the gauge diameter is too small.   Mar 9 2023, 08:42 PM
bkrantz   I have an idea: 1/8" thick rubber.   Mar 9 2023, 08:42 PM
bkrantz   Here's a 1/2" wide strip wrapped around t...   Mar 9 2023, 08:43 PM
bkrantz   Now it's a snug fit, and looks pretty good.   Mar 9 2023, 08:44 PM
bkrantz   Time to sort out the wiring, so connect the batter...   Mar 9 2023, 08:48 PM
bkrantz   I need a switched positive lead. I deleted the cl...   Mar 9 2023, 08:51 PM
bkrantz   That means time for a twin spade adapter.   Mar 9 2023, 08:52 PM
bkrantz   And a jumper lead.   Mar 9 2023, 08:53 PM
bkrantz   And isolating the power lead for the clock.   Mar 9 2023, 08:53 PM
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