First of the Texas Twins, First Build Options

[Puebloswatcop]

ooops

[Puebloswatcop]

Yep Guys, I am ging to buy a couple of new tools...A metal shrinking disk, a copper paddle for welding the holes closed and some other "Make it easier" tools. (IMG:style_emoticons/default/smash.gif) (IMG:style_emoticons/default/welder.gif)

[Puebloswatcop]

Didn't get a lot done yesterday, spent most of my day cleaning up storm damage.
But the door is stripped of all of the colored paint on the doorskin side,



And most of the colored paint on the inside. From this point on it is all hand sanding

[Puebloswatcop]

Got a bit more of the passenger door done today. Started off with a new tool. A small copper paddle for welding those nasty little holes and cracks, without blowing holes through your work.....

[Puebloswatcop]

It worked great and cut the time to fill in the unwanted holes way back.
It was really nice when ther was just a small ammount of material to be added to straighten out the door handle mount and the mounting hole.

[Puebloswatcop]

Time to weld up the holes the PO used to mount the side view mirror in the wrong place. The copper paddle really helped keep unwanted welding material out of the threaded holes in the mirror bracket. The last photo shows how far off the PO was when he drilled the holes and missed (yellow arrows) the mounting bracket (Green Arrows).

[Puebloswatcop]

Then I used a metal punch through the mounting plate holes to mark the approximate location of wear the new holes needed to be drilled. After making a slight nipple on the outer surface, I went back and center punched where the holes needed to be drilled. Then starting with a very small bit, I drilled holes. Didnt hit the thick steel bracket, so far, so good.

[Puebloswatcop]

Then I went back and enlarged the holes, being careful to only drill the outer skin and not go through the bracket underneath. After I completed the holes, I was about 1/32nd of and inch off center, but it will work out fine. Finattly I went in and re-tappedthe threads in the mounting bracket to make sure there were no problems.

[Puebloswatcop]

Today was hot, humid and miserable. I worked most of the day putting in the HVAC in the shop. But I wanted to do something for the 914, but it was going to be inside.

I recently bought a "lot" of FI parts, which included 2 Pressure sensors. One does not hold pressure, while the other one does. Problem being theat the one that holds pressure has something rattling around inside. Either way I figured I got 2 questionably re-buildable units.

I decided to work on the one that holds pressure. I shook it around trying to figure out where that rattle was coming from. I was looking it over, when I saw something inside the vent slots on the adjuster end of the valve. So I started by giving the outside a cursory cleaning so the wife would not get too upset when she found me working on it at the dining room table.

[Puebloswatcop]

Then I set about finding out what it was that was inside that vent slot. I discovered it looked like a mud ball of some type. For those who live in the south, it looked like a miniature mud dauber house.

So I took a plastic tooth pick and carefully crushed it until I could make small enough pieces that would come out through the vent slots. It took a while but I finally got it all out and viola, no more rattle.

[Puebloswatcop]

cleaned up the bushings and the rubber isolators that go to the mount. Normally I would have just replaced them but the metal busing is NLA and the damned rubber parts run $6.00 each plus shipping. so since they weren't torn or deformed. I just cleaned them up.

[Puebloswatcop]

So, as I cleaned up the body of the unit up, I finally located the part number 0-280-100-037, when I looked it up to check for fitment, it is listed as a 2.0 part, but as a bonus it says it is the european part, which gives better top end performance....BONUS

[friethmiller]

Then I went back and enlarged the holes, being careful to only drill the outer skin and not go through the bracket underneath. After I completed the holes, I was about 1/32nd of and inch off center, but it will work out fine. Finattly I went in and re-tappedthe threads in the mounting bracket to make sure there were no problems.

Nice job on this repair, Kevin. The PO didn't do you any favor drilling those holes where he did.

[bkrantz]

Then I set about finding out what it was that was inside that vent slot. I discovered it looked like a mud ball of some type. For those who live in the south, it looked like a miniature mud dauber house.

So I took a plastic tooth pick and carefully crushed it until I could make small enough pieces that would come out through the vent slots. It took a while but I finally got it all out and viola, no more rattle.

Those darned mud daubers will get into anything. I keep a small fire extinguisher on my deck next to the grill. Just incidentally I happened to look at the nozzle and found it plugged with mud. Probably not much use that way, so I cleaned it out, and then made a cap of aluminum foil.

[Puebloswatcop]

Then I set about finding out what it was that was inside that vent slot. I discovered it looked like a mud ball of some type. For those who live in the south, it looked like a miniature mud dauber house.

So I took a plastic tooth pick and carefully crushed it until I could make small enough pieces that would come out through the vent slots. It took a while but I finally got it all out and viola, no more rattle.

Those darned mud daubers will get into anything. I keep a small fire extinguisher on my deck next to the grill. Just incidentally I happened to look at the nozzle and found it plugged with mud. Probably not much use that way, so I cleaned it out, and then made a cap of aluminum foil.

I bet one good blast from the extinguisher would give the little creatures something to ponder... (IMG:style_emoticons/default/evilgrin.gif)

[worn]

Then I set about finding out what it was that was inside that vent slot. I discovered it looked like a mud ball of some type. For those who live in the south, it looked like a miniature mud dauber house.

So I took a plastic tooth pick and carefully crushed it until I could make small enough pieces that would come out through the vent slots. It took a while but I finally got it all out and viola, no more rattle.

Those darned mud daubers will get into anything. I keep a small fire extinguisher on my deck next to the grill. Just incidentally I happened to look at the nozzle and found it plugged with mud. Probably not much use that way, so I cleaned it out, and then made a cap of aluminum foil.

I bet one good blast from the extinguisher would give the little creatures something to ponder... (IMG:style_emoticons/default/evilgrin.gif)

I dunno. Seems like when Bugs Bunny plugs up Elmer’s blunderbuss it is Elmer with soot all over him.

[Puebloswatcop]

Haven't been getting to work on the car much this week, but I now have some climate control in the shop that will make working much more comfortable.

[Puebloswatcop]

Back to working on the door. I got a couple of new tools to help things along. A tiny hand sander and a miniature belt sander.

[Puebloswatcop]

Now after a couple more hours with the new sanders, it is almost ready for primer. Those areas that can't be reached with sand paper and sanding tools will be cleaned with acetone and prep spray and then the inside of the door can be primed. Then I will skin the outside of the door with body filler and sand it out flat....hopefully on the first try,

[Puebloswatcop]

Back to work on the passenger door.... As I stripped more paint I found a hole I hadn't noticed near the earlier repair. So I welded it closed and cleaned the area up again.