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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   Mixed with a bit of dye, the oil glows orange.   Jun 20 2023, 06:54 PM
bkrantz   I poured the entire bottle into the oil fill, and ...   Jun 20 2023, 06:55 PM
bkrantz   I first ran the engine for about 30 seconds, to se...   Jun 20 2023, 06:57 PM
bkrantz   I then did 60 seconds (idle), 5 minutes (idle), an...   Jun 20 2023, 07:00 PM
bkrantz   I then did two sessions of about 8 to 10 minutes, ...   Jun 20 2023, 07:07 PM
bkrantz   I spent a lot of time looking with UV, and took a ...   Jun 20 2023, 07:11 PM
bkrantz   I also found a path of oil on the angular case pie...   Jun 20 2023, 07:31 PM
bkrantz   Bottom line, I am pretty sure that at least one th...   Jun 20 2023, 07:35 PM
930cabman   I feel your pain, built a 2056 and she runs great....   Jun 21 2023, 11:15 AM
Puebloswatcop   Bob, Sorry you didn't have better luck with th...   Jun 21 2023, 05:05 PM
bkrantz   I took another look today, with regular light. He...   Jun 22 2023, 08:48 PM
bkrantz   Hard to see, but a possible second leak might be f...   Jun 22 2023, 08:49 PM
bkrantz   And so I stripped everything off the top of the mo...   Jun 22 2023, 08:50 PM
bkrantz   This time I put a bright red rag in the oil filler...   Jun 22 2023, 08:52 PM
bkrantz   Underneath, I removed the muffler, shift rod, and ...   Jun 22 2023, 08:54 PM
bkrantz   A piece of cardboard on each side to protect the s...   Jun 22 2023, 08:56 PM
bkrantz   Then time to undo the cross beam bolts and the tra...   Jun 22 2023, 08:59 PM
bkrantz   Ready for the second attempt to find and fix oil l...   Jun 22 2023, 08:59 PM
Cairo94507   Man, I feel for you. Gotta love your determinatio...   Jun 23 2023, 07:55 AM
Puebloswatcop   Bob, I gotta say your love and dedication to this ...   Jun 23 2023, 04:52 PM
bkrantz   OK, here with go. Wait for a surprise(?) ending. ...   Jun 23 2023, 06:47 PM
bkrantz   Under UV, the same indication that the galley plug...   Jun 23 2023, 06:48 PM
bkrantz   No indication of leaks from the front seal.   Jun 23 2023, 06:49 PM
bkrantz   Some older-looking oil on the case flange and the ...   Jun 23 2023, 06:51 PM
bkrantz   Also left-over(?) oil on the rubber.   Jun 23 2023, 06:52 PM
bkrantz   Again the front seal looks dry--yay!   Jun 23 2023, 06:53 PM
bkrantz   Looks like the stock front plug is also leaking.   Jun 23 2023, 06:54 PM
bkrantz   Oil pooled on top of the filter, almost certainly ...   Jun 23 2023, 06:56 PM
bkrantz   As planned I went to remove the oil cooler, but th...   Jun 23 2023, 06:57 PM
bkrantz   The cooler seals actually look pretty good. But t...   Jun 23 2023, 07:00 PM
bkrantz   Yup, there's my creative plumbing for the dual...   Jun 23 2023, 07:03 PM
bkrantz   No denying now--this looks like a real leak.   Jun 23 2023, 07:04 PM
bkrantz   Looks leaky and cruddy.   Jun 23 2023, 07:05 PM
bkrantz   I pulled all the sheet metal on the right side for...   Jun 23 2023, 07:06 PM
bkrantz   And the oil filter mount. This gasket looks good.   Jun 23 2023, 07:07 PM
bkrantz   And finally the galley plugs. The upper one looks...   Jun 23 2023, 07:08 PM
bkrantz   And the lower one, too.   Jun 23 2023, 07:09 PM
bkrantz   And the stock plug.   Jun 23 2023, 07:09 PM
bkrantz   But the smaller plug on the right side, on the cas...   Jun 23 2023, 07:11 PM
bkrantz   I have to think about what to do with the oil pres...   Jun 23 2023, 07:13 PM
bkrantz   But I would rather try something different, probab...   Jun 23 2023, 07:14 PM
FlacaProductions   I would see if you could find a 42 Draft Design re...   Jun 23 2023, 07:35 PM
930cabman   Great detective work Bob, it's probable a bit ...   Jun 24 2023, 05:58 AM
Cairo94507   Congratulations on chasing that down to its likely...   Jun 24 2023, 07:12 AM
bkrantz   Congratulations on chasing that down to its likel...   Jun 24 2023, 07:53 PM
bkrantz   Starting to put things back together today. Step ...   Jun 24 2023, 07:54 PM
bkrantz   Step 2: clean the plugs.   Jun 24 2023, 07:55 PM
bkrantz   Step 3: apply thread sealant.   Jun 24 2023, 07:56 PM
bkrantz   Step 4: insert plugs and make TIGHT.   Jun 24 2023, 07:57 PM
bkrantz   Including the plugs on the cooler casting boss.   Jun 24 2023, 07:58 PM
bkrantz   Now thinking about the oil pressure sender. I kno...   Jun 24 2023, 08:04 PM
bkrantz   But the VDO threaded stud is longer than stock.   Jun 24 2023, 08:06 PM
bkrantz   And the VDO sender bottoms out in the case hole.   Jun 24 2023, 08:07 PM
bkrantz   I rummaged through my miscellaneous hardware and f...   Jun 24 2023, 08:09 PM
bkrantz   Plus a bit of thread sealant.   Jun 24 2023, 08:10 PM
bkrantz   I sure hope this cures the worst leak I had.   Jun 24 2023, 08:11 PM
bkrantz   A quick check on electrical conductivity--looks go...   Jun 24 2023, 08:12 PM
bkrantz   One more thing. The stock sheet metal hole will n...   Jun 24 2023, 08:14 PM
bkrantz   I got out my die grinder for the first time since ...   Jun 24 2023, 08:16 PM
bkrantz   I painted the raw edges (primer and black). The r...   Jun 24 2023, 08:17 PM
bkrantz   Then a bit of vinyl edging.   Jun 24 2023, 08:18 PM
bkrantz   This should work.   Jun 24 2023, 08:18 PM
bkrantz   Mini-marathon today to see if I can get everything...   Jun 25 2023, 04:21 PM
bkrantz   That means I get to use my special tool. I was ab...   Jun 25 2023, 04:22 PM
bkrantz   Then the oil cooler, with new seals.   Jun 25 2023, 04:23 PM
bkrantz   As is traditional, a dab of grease to hold them in...   Jun 25 2023, 04:24 PM
bkrantz   Cooler installed, but...   Jun 25 2023, 04:24 PM
bkrantz   Not enough clearance to bolt on the oil filter mou...   Jun 25 2023, 04:25 PM
bkrantz   So, remove the oil cooler and give the new filter ...   Jun 25 2023, 04:26 PM
bkrantz   And bolt on the mount with a new filter. BTW, I h...   Jun 25 2023, 04:28 PM
bkrantz   Cooler back on, and make double sure the seals are...   Jun 25 2023, 04:30 PM
bkrantz   With everything closed up, I did another cleaning ...   Jun 25 2023, 04:31 PM
bkrantz   Time to start with sheet metal and other air cool ...   Jun 25 2023, 04:33 PM
bkrantz   Uh-oh. This also does not clear the VDO pressure ...   Jun 25 2023, 04:33 PM
bkrantz   Another 10 minutes with the die grinder and the ha...   Jun 25 2023, 04:35 PM
bkrantz   Before I forget, a new head gasket for the intake ...   Jun 25 2023, 04:36 PM
bkrantz   And another small thing: the Hall sensor and brack...   Jun 25 2023, 04:37 PM
bkrantz   Check the clearance with the trigger wheel.   Jun 25 2023, 04:38 PM
bkrantz   OK, with motor mounts and the cross bar, ready for...   Jun 25 2023, 04:39 PM
bkrantz   Housing installed.   Jun 25 2023, 04:40 PM
bkrantz   Including the 2 bolts on the side for the oil cool...   Jun 25 2023, 04:41 PM
bkrantz   Right side upper sheet metal.   Jun 25 2023, 04:42 PM
bkrantz   Thermostat spring and cable.   Jun 25 2023, 04:42 PM
bkrantz   Right side intake manifold.   Jun 25 2023, 04:43 PM
bkrantz   Crank trigger wheel for good. I think I got it in...   Jun 25 2023, 04:44 PM
bkrantz   Blower cage.   Jun 25 2023, 04:44 PM
bkrantz   Left side duct work.   Jun 25 2023, 04:45 PM
bkrantz   Right side duct work.   Jun 25 2023, 04:45 PM
bkrantz   Alternator and belt.   Jun 25 2023, 04:46 PM
bkrantz   Alternator lead to starter, and insulated with 3M ...   Jun 25 2023, 04:47 PM
bkrantz   Front sheet metal.   Jun 25 2023, 04:47 PM
bkrantz   Speaking of leads, I made a new jumper to connect ...   Jun 25 2023, 04:48 PM
bkrantz   It goes here.   Jun 25 2023, 04:50 PM
bkrantz   That's it. The motor is ready to install (aga...   Jun 25 2023, 05:11 PM
Cairo94507   Fingers crossed. :beer2:   Jun 26 2023, 06:39 AM
bkrantz   Fingers crossed. :beer2: Thanks.   Jun 26 2023, 07:06 PM
bkrantz   Ready to go up.   Jun 26 2023, 07:07 PM
bkrantz   Engine bolted in place. Then the two bottom sheet...   Jun 26 2023, 07:08 PM
bkrantz   CV joints bolted to flanges, with new gaskets and ...   Jun 26 2023, 07:10 PM
bkrantz   Shift rod.   Jun 26 2023, 07:11 PM
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