Been a bit slow BUT...

Things have been a bit slow working on the car in the last few weeks, but the engine is just about ready to get dropped in, and once it is, it's a downhill run to get it ready to drive. I don't see many more roadblocks, at least for awhile.

Meanwhile for Christmas I got all kinds of goodies - like 1200 watt work lights, ratcheting wrenches, various breathing apparatuses (apparati if you will), a shop vac and more!

Engine Prep Continues

Today I got the broken stud out of the engine block. Also, I bought a tap and new studs so once the engine is off the cradle, I can retap the bad threads and everything will be good as new.

I test fit the EGR plug in it's new location and there IS room for it, although it will be tight. Also, I came up with a great way of blocking off the open ports - by using the old fitting, and welding a piece of scrap metal to the top of it. Oh yeah, things are going pretty good again :-D

Engine prep starts

I wrapped up a bunch of loose ends on the chassis and then got to work preparing for the engine install. First I removed the smog related stuff and removed the belt and cleaned it up a bit. It's certainly not a show-queen, but it's a lot better :-P Then I put the dead-pulley in place where the A/C compressor was and re-routed the belt. After that I bolted the transmission mount up to the frame.

Before








After








So left to do before installing the engine and transmission are these:
1) Fix a broken exhaust manifold stud and a stripped stud. I want someone who has done this before to help - I'm nervous because the aluminum block is softer than the stud.
2) Re-route the EGR using the smog pump stuff. (requires some ingenuity and welding). I need someone who can weld to hook me up on this one.
3) Block off all open EGR, smog, and vacuum openings. I hear that the EGR port is really hard to block off because the threads are odd shaped. Hopefully the smog port wont be too bad. I might just order an EGR blockoff kit just for the EGR plug. What to use to block off the vacuum lines? I heard irrigation plugs will work.
4) Swap out the oil pan. I can't do this one until the engine is up on the hoist. That should be fun...

Brakes done!!! Whew.

This morning I headed over to NAPA to pick up my brake line stuff...again :-P So at long last the brakes are complete. Also, the fuel lines are connected to the fuel tank and run up to the engine bay. I ran the vapor line from the back toward the front and have mocked up where the battery cable will go. I haven't decided for sure where to mount the battery - mainly because I don't understand the instructions :-D

In preparation for the engine installation, I thought it would be a good idea to go ahead and install the heater box. Here's a pic of he box installed. So now I really do have to figure out what I'm going to do with the EGR and Smog stuff.

Brakes are about 95% done

So I went back to NAPA and the guy that ordered the stuff realized he ordered the wrong thing and went back to the catalog to remedy the dismal situation. Only then did he realize, and soon thereafter portray to me, the actual depth of dismality of said situation. NAPA does not even have the fitting that I need in their catalog. Which means instead of 2 fittings, I now have redo the plan for that section and I now need 4 fittings and 2 new lines. The good news about this is - NAPA can't really screw this one up.

It will be Saturday before the parts are here, but I think that is ok because I have everything I need to run the fuel lines and battery line. I will knock those out in the next day or so then spend most of vacation working on engine preparations.

Still aiming for a Jan. 1 engine drop-in.

Brakes are about 80% done

So I ended up deciding to go with pre-flared lines and fittings. I ordered some stuff through NAPA for next day pickup and this evening I finished about 80% of the brake lines with Tom. All I have left now is to run the long line from the ABS unit to the rear and I have to go back to NAPA to get 2 fittings (they gave me the wrong thing!) Other than that the brakes are finished. Hopefully I can run the fuel lines tomorrow and then get the battery relocation finished during the holiday and can drop the engine in on new years day!

Egad brakes suck...

I've basically been treading water for a few days on the brake lines. The (main) trouble is that the tool I bought to flare the brake lines doesn't work. I'm not sure if it is because the lines are too hard or if the tool just sucks, but it is not properly flaring. So I've pretty much narrowed it down to 2 options after trying a few things:

1. Get a more expensive flare tool.
Upside: All the lines would be perfect fits.
Downside: More chance of a leak from a bad flare, chance this tool will suck too.

2. Buy pre-flared lines of the 'right' size and adapters for the ends.
Upside: No flares to do! No chance of a misshapen flare. No wasted money on bad/once used tools.
Downside: Adapters means more chances of a leak, lines wont be perfect fits, have to find all the right sized adapters.


Well, I mounted the Anti-Lock Brake System Controller last night. This was a little challenging because the older style models are huge, and the manual doesn't have anything in it about where to mount it. I think the typical donor car does not use ABS. But given I'm building this car to withstand weather, I think I want ABS for the rain. Although an on/off switch would be awesome. Here is a pic of the mounted unit, as you can see I had to make some stuff up for it because they don't have a prefabbed mounting position on the frame.

Cockpit Aluminum

I spent 8 hours in the garage today riveting panels. Lucky for me it warmed up a lot today! Diana came out and helped for awhile which was really helpful for the passenger footbox. Here's a few pics:

Steerin'

With the pedals in and the hydrobooster loosely fitted, I decided to go ahead and start on the steering system even without my back-ordered part. I got the donor steering rack in and bolted up - only to realize that it seemed really loose. I poured through the bags of donor parts and found the steering rack bag which had some rubber bushings I forgot to put in. SO, I had to unbolt it and remove it and slap those bushings in. It wasn't too bad though, so after I put the rack in the 2nd time, I attached the tie rods and gave the car a 'rough alignment'.

Then I deciphered some more instructions and despite the manual giving me the wrong part numbers - and wrong box location - I managed to get the upper steering column mostly fitted. I had to grind a bracket down a bit so it would lay flush, but it wasn't too tough. Once that back-ordered part comes in the steering will be finished.

A nudge forward

Last night, Josh and Brandon came out to help work on the car. Josh worked on fitting the hydrobooster while Brandon and I mounted the fuel filter. Brandon took a drill-face picture of me, and that is the only picture that I have from last night to post right now. I'll take some pics after the hydroboost is done and the pedals are finished.

I got gas

Chronicles of a gas tank. Diana scrubbed the tank yesterday in preparation for painting, and when I got home I sprayed the first coat. Meanwhile, Tom headed over and we torqued the suspension to the proper specs and finished a few lingering suspension issues. After that, I sprayed a final coat on the tank and we hoisted it up onto the frame.

Rear Suspension/Axle

This will be quick and short because it's about 2 am and I have just finished working on the car... My goal for the day was to complete assembly of the rear end. I got home about 6 and worked straight through until after 1. But I got it done! Here is a pic of the assembly. It's kinda hard to tell what is what in this pic, but you can get an idea.


There was a lot of drilling...a LOT of drilling. I broke 2 bits including my new 9/16 metal drilling bit. It made me sad because I had just bought it the other week, but then it made me feel kinda awesome for breaking a drill bit so huge :-D.


The evening had a few frustrating moments and several puzzles solved. I didn't get a chance to eat dinner, and I nicked the back of my hand with Carl's grinder - (that is a nick you won't do twice!) But once Everything was done, I put the wheels on and got to hop up and down to test out the suspension. It's official, the car is now a rolling chassis!! It probably wont roll very straight or well, since the steering hasn't been done yet, but it will roll!