Just got around to reading all 65 pages of your amazing project, Bob. Fantastic job so far !!!

Subscribed to see the finishing touches come about



Question ... what is this tool called?

Air needle scaler

Thanks, Mark!

Interesting tool. Could be useful.

More shiny new bolts arrived today, from Belmetric.

Now the tie rods have bolts.

And more pretty bolts now for the underside, just to make the purists happy.

I then tried to torque the ball joint retainer rings. I used a floor jack to keep the socket from slipping, but still could not get the big torque required (25 map or 180 ft-lbs). Any suggestions?

Following on from testing electric motors yesterday, I started cleaning crud, overspray, and undercoating.

Heater blower components.

And the wiper system, before cleaning off 50 year old grease.

And after.

That's the same method I used.
Struggled with it, but got it to work and tighten up the ball joints some how.

More prep on the wipers. I found one broken wire.

Soldered, and I treated the fabric insulation and seals where the wires enter the motor housing with 3M liquid rubber.

Wiper gear installed, from the top.

And the bottom.

Getting started on the headlights. These are in the same state when I took the car apart. Into the acetone bucket!

The motors need cleaning up, too, with PO undercoating and messed up wiring.

And getting started on the fresh air stuff--also with undercoating and overspray.

Have a swear jar handy when you put that box in......

have you got a screen for fan/vent box?
good idea (later cars) - helps keep leaf muck out.

Looking great as usual. I'm working on the same stuff here. Did the headlight buckets today and plan on tackling the motors this week. Any advice or wires I shouldn't cross ?

@djway is right about the airbox install. I learned a few tricks which will hopefully save you a few pennies in the swear jar...

https://youtu.be/Uhs6pedBOXM

I already have one working (see later posts).

Thanks--I got one with the new gaskets.

Thanks, Ian. I like your method--will give that a try.

More progress on the fresh air box. Disassembly.

And then the tedious, PIA removal of undercoating.

I know I have ranted about this before, but WTF was the PO thinking? I am not a fan of legal restriction, but I would like to outlaw cheap undercoat spray. OK, rant over.

So far, GoofOff seems like the best solvent. It does eventually remove the undercoating (with lots of rubbing) and (almost) does not react with the plastic.

I needed a break, and also to take care of things that will be blocked by the air box. That includes the grommet for the 3 heater cables. This was also a bit of a pain.

Enough annoying work for today. Instead I got together all the parts for the heat blower.

Much more fun to put clean and shiny parts together.

And mount it in the engine compartment.

I just need one of these for the connection. (borrowed photo)

Still working on multiple components at the same time. Making progress with stripping overspray, undercoating, and (unfortunately) the original paint from the headlight brackets.

And progress on cleaning the blower section of the fresh air box. I got most of the undercoating off, and then tackled the fossilized duct tape that the PO used to keep the power plug in place.

This was not coming off with any solvent, at least that would not erode the plastic housing, so I tried shaving, using several new razor blades and lots of patience.

Mostly successful, with just a little damage.

After wiping with GoofOff, which reacts slightly with the plastic, the shine cam back.

Next, I opened up the blower section so I could replace the baffle rings. Somehow the PO got undercoating in here (see baffle on the left).

The baffles are easy to take apart.

New rings, part of the 914 Rubber kit.

Since I was getting ahead of myself with the fresh air box, since I need to install the dash control levers and cables first, and that means I need to install the dash. And before doing that, I need to replace the top padded vinyl and the face vinyl. Note what seems to be a buckle along the lower edge.

Another view of the lower dash edge. This should be straight, right?

So much progress... Much of what you do is a very good reference for me later this year... Keep posting with many pictures!

I agree - great reference.

Has anyone (admins) considered this for the "Classics" thread?

Will do!

Got the fresh air box back together. The little circle clips are a PIA. And, yes, I did break off one of the plastic tabs.

I also cleaned up the control levers. Quite a bit of dirt and some corrosion.

Cleaned up.

I used some fine emery paper on the contacts.

Check this fresh air fan switch for continuity on all 3 speeds before installing. I didn't so didn't have all the fan speeds once installed and had to remove the switch again with all the associated cuss words to sort the issue.

Looking good.....