Randy's project(s) thread

[Randy]

Quick History

July '06 - Bought a '74 2.0 to replace my dying/dead '71 1.7. The car had been sitting for about five years, and I had helped the previous owner (a friend) get the car back on the road.

Work we did together:

Replaced rubber fuel lines from tank back
Painted exterior of fuel tank with POR-15
Serviced brake system (bled), replaced rear calipers used, working pair
Replaced FI air/fuel seals
Changed OilOnce the car was on the road, we were pleased with the car's running performance, though the motor smokes and leaks a lot of oil. The geaxbox is in very good shape, and shifts well in all gears.

The test drive, note the old steering wheel:
http://farm1.static.flickr.com/22/178156308_64ed55afa6.jpg

Here's how it was back in July:
http://farm1.static.flickr.com/59/182991955_81bd258fbd.jpg

Racing at the Sonoma County Auto-X in Aug, 06:

http://farm1.static.flickr.com/67/217715338_89977ac7aa.jpg

[Randy]

The suspension is well suited for auto-x, and the one of the previous owners did set it up for light racing. There were stiff springs with red Konies in the rear, a heavy sway bar up front (no rear bar), and stiff torsion bars. I haven't had the front end apart yet to see what size torsion and sway bars are, and I don't know what types of struts are up there, though they're probably Koni reds.

What I've done to the suspension thus far:

Replaced the rear Koni reds and springs with a set of Koni yellow sports with 185 lb springs.
Replaced four position adjustable sway bar drop link system with a fully adjustable system
Installed Falken Azenis RT-615 tiresThat's it! It handles great, though here's the list of things to do:

Phase 1

Tubro Tie Rod Kit (purchased)
Replace wheel bearings (front - need to purchase)
Smart racing bump steer kit (need to purchase)
R and R front rotorsPhase 2

5-lug rear hubs (purchased)
Rear wheel bearings (need 1, have 1)
Struts with raised spindles, 5-lug hubs, aluminium cross member, new front rotors (purchased)
19 MM master cylinder (need)
S Calipers (have, need to inspect pistons for wear)
Remove stock proportioning valve, replace with T (have)
ATS 15 x 7 Wheels and tires (have wheels)Old springs and shocks:
http://farm1.static.flickr.com/11/182991443_d816791832.jpg

Koni Yellows with 185 lb springs:
http://farm1.static.flickr.com/181/379037516_185b16f110.jpg


ATS Wheels:
http://farm1.static.flickr.com/124/379037490_dd7b2ba7d3.jpg

Old drop links:
http://farm1.static.flickr.com/167/379037615_61389a29dd.jpg

[Randy]

The pedals were a rusty, binding mess and I replaced them with a freshly set that I rebuilt using bronze bushings and POR-15.


Replaced cluster with rebuilt cluster, bronze bushings, POR-15
New OEM throttle pedal
I should also mention that the clutch cable was replaced recentlyNew:
http://farm1.static.flickr.com/114/315351056_8d38b9d16f.jpg

[Randy]

Lots more to post! Out of time for tonight. I'll leave you with a few photos of today's fun:

This is how we move motors out in California:

http://farm1.static.flickr.com/151/379000293_7eb7187930.jpg

The fleet:
http://farm1.static.flickr.com/160/378999074_28f2f95a12.jpg

Self Portrait:
http://farm1.static.flickr.com/126/378998091_275ec53f66.jpg

[Randy]

A new bushing:
http://farm1.static.flickr.com/139/339872681_ddd2483528.jpg

Out with the old, in with the new:
http://farm1.static.flickr.com/137/323327748_fe0f044df9.jpg

Interior is beginning to take shape:
http://farm1.static.flickr.com/110/315351350_1615815aab.jpg

[Randy]

It's hard to believe that it's already been a month since my last post. Everything is coming together fast now, and I owe Soren a huge thanks for working so fast on the machine work. He's a real artist and a master of his trade.

I pulled the motor last weekend, stole it's heads and have been collecting parts like a mad man. I've resealed the transaxle, spent hours cleaning it and other parts, have started painting bits and Soren has finished up all the case work.

http://farm1.static.flickr.com/175/410059817_15916197e1.jpg


I wish there was an easy way to clean off all the glue. Going to be doing some rust stopping this weekend:
http://farm1.static.flickr.com/184/410059075_a4f4b57bdb.jpg


Here's the 2.0 I pulled from the carcass:
http://farm1.static.flickr.com/150/410057565_87eb4c6baa.jpg

[Randy]

Replacing seals and bushings in the gearbox:

http://farm1.static.flickr.com/169/412387010_3f7c47449d.jpg

http://farm1.static.flickr.com/131/412387078_4af8ee27fe.jpg


http://farm1.static.flickr.com/180/412387139_d2a2809176.jpg

[Randy]

Soren worked on the case today making modifications for the figment of a a larger, high pressure oil pump. I haven't photographed that mod yet, but pictured are some of the mods he made to the pump so that it would clear the cam bolts and gear. The two small galley plugs on the flywheel side of the case were removed, the holes tapped and then plugged.

We're ready to start the bottom end assembly come next week. Lots for me to do in the mean time.

http://farm1.static.flickr.com/177/416121866_0854ee1fb1.jpg

http://farm1.static.flickr.com/155/416121997_cbda96aed8.jpg



http://farm1.static.flickr.com/145/416122158_b7640b564d.jpg

http://farm1.static.flickr.com/167/416122396_0007751c40.jpg

[Randy]

The rest

http://farm1.static.flickr.com/164/416122441_c2fb017995.jpg

http://farm1.static.flickr.com/130/416122596_38d4f7e5f9.jpg

http://farm1.static.flickr.com/155/416122640_81213c002b.jpg

http://farm1.static.flickr.com/133/416122846_71715370d1.jpg

[Randy]

Painted the intake runners.

http://farm1.static.flickr.com/150/416212788_7919de3a84.jpg

http://farm1.static.flickr.com/128/416212846_a7a554cde6.jpg

[South Elgin 914]

Hi Randy. The oil pump mod looks good. I see he is opening the holes here. The last picture looks like a tap. Is that what that is? Is that one of the special fluteless taps? I have never used one. Just curious. I wouls like more information on this mod. I plan on reworking a motor this Spring.

[Randy]

Hi Randy. The oil pump mod looks good. I see he is opening the holes here. The last picture looks like a tap. Is that what that is? Is that one of the special fluteless taps? I have never used one. Just curious. I wouls like more information on this mod. I plan on reworking a motor this Spring.

You know, I don't know all the details. The last picture does show him using a tap, but I don't recall the type. It was attached to the mill (if that helps). I know we're using plugs that Mercedes uses to fix galleys on their cars. I'll see if I can get more info this week.

[grantsfo]

Great photo work on this project! Feel like I'm at the machine shop!

[Randy]

Great photo work on this project! Feel like I'm at the machine shop!

Thanks! I'm trying to make this interesting.

[Randy]

The previous owner of one of the 2.0s I took apart plated all the engine tin with nickel or cadmium. It might have looked good at some point, but it's pretty blemished now. Rubbing on it too much just takes it off, so I started prepping it for paint here:


http://farm1.static.flickr.com/168/417189572_9d1801ae3c.jpg

That's better:
http://farm1.static.flickr.com/125/417189981_31a2420a53.jpg

http://farm1.static.flickr.com/128/417190222_920c834e51.jpg

http://farm1.static.flickr.com/152/417190423_a7fa6560ba.jpg

[Randy]

I might leave the plenum alone. It's plating it is in pretty good condition and would be bit of a pain to paint. We'll see, I might change my mind yet.

http://farm1.static.flickr.com/130/417190275_69f7921ae3.jpg

http://farm1.static.flickr.com/170/417190092_e050f43dde.jpg

It took me a few hours of scraping, soaking, scraping, wire-wheeling, etc, to get the stainless to shine up:

http://farm1.static.flickr.com/149/417189364_2cd8470812.jpg

One of the four new injectors:
http://farm1.static.flickr.com/183/417190669_c1226477d5.jpg

[bleyseng]

Dude, Porsche still sells the proper PCV for the oil filler. What is that fitting?:eek:

[South Elgin 914]

The tins are looking great. It is amazing what a coat of paint will do.
Keep the pics coming.

[Randy]

Dude, Porsche still sells the proper PCV for the oil filler. What is that fitting?:eek:

DPO. I have spares, really no excuse for not changing it out. I'll do that.

[Randy]

I didn't get as much done as I would have liked today, but I had a nice morning and then had Sylvie and friends visit throughout the day. A nice trade off, and a nice break from the pace I had going last weekend.

Today I got the injectors setup on the fuel rails. Both rails are plugged, as I'm considering bypassing the cold start injector all together. Both the cold start injector and fast idle valve were disconnected and blocked off on the car before I pulled the motor and I never had any problems starting the car during the winter. It never gets cold, and only a few mornings are below freezing up here. We'll see though, and it's not a big deal hooking it up later.

I also reconditioned the distributor by pulling it apart short of removing the shaft from the housing. I was still able to clean and lube the advance weights without removing them, and made sure everything else was in order and cleaned while I had it apart. I also installed a Permatex Ingnitor unit and ditched the points and condenser. I've heard horror stories of these failing, so I'll be sure to keep a set of points on hand. I tested the vacuum advance and retard canister, and it works great. Actually, the one I pulled off the car was bad and ended up using one of my spares. Replaced the o-ring seal, used a new cap and rotor and put some fresh dizzy lobe grease on the trigger points lobe. Looks almost like new now.

Here are the photos:
http://farm1.static.flickr.com/132/418380161_4a4712c8f9.jpg

http://farm1.static.flickr.com/145/418380286_d005f608f4.jpg

http://farm1.static.flickr.com/148/418380458_907b6fbbb8.jpg

Dismantled Distributor:
http://farm1.static.flickr.com/161/418380719_7c7bb87193.jpg

[Randy]

http://farm1.static.flickr.com/171/418380920_c47a5c1730.jpg

http://farm1.static.flickr.com/146/418381069_7eadd9ac27.jpg

The rotor is new and I put a little dielectric grease on top:
http://farm1.static.flickr.com/177/418381232_34cc03c756.jpg

http://farm1.static.flickr.com/180/418381409_e86863bde8.jpg

That's all for now! Going to try to get the motor assembled and installed by the 19th. Wish me luck!

[Randy]

http://farm1.static.flickr.com/161/418380094_af8438e1d4.jpg

(you have to have met me to understand this photo)

[gms]

Randy...err Gomer :D

[Dave_Darling]

(you have to have met me to understand this photo)

Dude, I've met you--even hung with you for a good while--and I still don't understand the photo!! :D

--DD

[Randy]

It's the new me!

[bleyseng]

Lookin good!:D

[davep]

Is there a before photo?

[Randy]

Went to Soren's today and media blasted some more parts (pictured) and then painted them (not pictured). Spent a good chunk of time with the jet washer doing a final cleaning on the case. Ran high pressure water through it and got out all the left over shavings that were leftover from the oil pump galley and galley plug modifications. Once washed and rinsed and air blasted, I set the case halves on top of his kerosene heater to dry off. Oh, and I did the same (washed, etc) to the push rod tubes. Guess I'll paint those tomorrow as well.

At the end of the day we got the rods onto the crank. We'll get the bearing, dist drive and fan mount on tomorrow AM. I'm thinking we'll probably get the entire bottom end together tomorrow as well. Cross your fingers for me.

Photos:

Pre-paint:

http://farm1.static.flickr.com/157/419530603_ef3f6caee1.jpg

High output pump

http://farm1.static.flickr.com/174/419530657_8c36f877a0.jpg

Oil galley mod for the high output pump
http://farm1.static.flickr.com/146/419530774_2bf2ec25c0.jpg

Oil galley mod for the high output pump
http://farm1.static.flickr.com/157/419531093_d392a77717.jpg

[Randy]

The rest of today's photos:

Drying one of the case halves on the kerosene heater
http://farm1.static.flickr.com/131/419531220_6bee508900.jpg


Connecting rods with bearings
http://farm1.static.flickr.com/148/419531348_23862d7701.jpg

One of the rods with bearing
http://farm1.static.flickr.com/181/419531481_0769ea7c21.jpg

[Randy]

Here's the crank and crank with rods (and Soren!):

http://farm1.static.flickr.com/126/419531693_edd9904c97.jpg

A little bigger than I normal:
http://farm1.static.flickr.com/162/419531855_0c93cba6c8_b.jpg

[Randy]

You can always see the full-res versions of these and other photos at http://www.flickr.com/photos/pixelrandy/sets/72157594579846476/

[Randy]

Didn't get quite as far as I wanted to today, but we're still on schedule.
Crank and rods ready for installation:
http://farm1.static.flickr.com/157/420653831_617a90b214_b.jpg



Though-bolt and washer, coated with Permatex Gasketsinch. This stuff is tried and true. I know some people are using other products, but this stuff works great (though is a bit messy):
http://farm1.static.flickr.com/169/420653891_a5770b7fe1_o.jpg


Through-bolt held in place by the anti-vibration shim:
http://farm1.static.flickr.com/145/420654005_d0808b995a_b.jpg

Crankshaft and through-bolts installed:
http://farm1.static.flickr.com/181/420654149_6ed3f669ab_b.jpg

[Randy]

Some more photos of todays progress.

We got the Raby 9550 cam installed on a -7 cam gear. No slop in the lash, but not too tight. The end play hasn't been set:
http://farm1.static.flickr.com/133/420654675_814fdb9885_b.jpg


Almost ready! Just need to install the oil baffle plate and pickup tube:
http://farm1.static.flickr.com/126/420654863_a05618348f_b.jpg


I hope the Raby 9550 was a good choice. My options were pretty slim since I'm sticking with D-Jet:
http://farm1.static.flickr.com/154/420654964_2bab6e1cb5_b.jpg

[Randy]

Just a few more for the day.

Testing fitting the oil pump again to make sure it clears the cam's bolt heads:
http://farm1.static.flickr.com/145/420655329_ff8b14d57b_b.jpg


Just makes it:
http://farm1.static.flickr.com/181/420655171_dcadf160f0_o.jpg

[South Elgin 914]

Randy

What are you going to use to seal the case halves? Also what will you seal the jugs to the case with? Fairly soon, I plan to tear my 2.0 down because of severe leaking.

[Randy]

What are you going to use to seal the case halves? Also what will you seal the jugs to the case with? Fairly soon, I plan to tear my 2.0 down because of severe leaking.

Hi!

We used Permatex Form-A-Gasket (used to be called Gasketsinch) for sealing the case halves - a thin even layer on one case half, just on the outer sealing surfaces.

If I recall, you seal the jugs to the case with the red, high temp silicon RTV.

I'll let you know for sure once we get there (Friday likely).

[Randy]

I accidentally left my camera at home today, so no photos. We finished the bottom end entirely though! Hooray! More later.

[Randy]

Though there are a few hold ups. Actually, we've been pretty lucky that there haven't been any real snags thus far. Grant mailed the pistons rings last week, but upon opening the box for the first time yesterday I discovered that they left out the sealing rings. Blah. We talked them into overnighting the missing rings, so they should be here in the morning.

We're having trouble locating the magic 16x1.5 (I think that's the pitch) tapered plugs for the galley holes Soren tapped. It's a Benz part used for fixing some of the old diesel blocks, but they're back ordered. We're going to start savaging through old Benz cases in the AM in hopes of finding a few.

The heads aren't finished yet either and most likely won't be done tomorrow. In the end, it's OK! I really need a weekend day or two to wrap up the minor rust repair work I need to do the hell hole. GMS will be here Monday, then he can help me wrap it all up on Tue/Wed. We can slap the suspension on his shell at that time as well.

I still made headway today. We got the deck height shim situation sorted out. We're going with 51 thousandths and I won't be running head gaskets. This number may change a little once I CC the heads and piston dish. He's not comfortable going any lower than 40 thousandths, so, well, that's all I can say about that until we get some more numbers.

Did a few other things as well to keep busy. Installed a few seals, cleaned and painted a few more parts, took the heads apart, blasted some bits. We've got a full day tomorrow, though it's all a little uncertain what's going to happen at this point. If the rings come in, then I can likely get the pistons and cylinders wrapped up. Also need to set the end play, pickup the fuel hose, vacuum lines, blah blah blah.

Pics:

As the block looked this AM:
http://farm1.static.flickr.com/155/422780129_f758eb683f_o.jpg


Here's a shot of the oil pump:
http://farm1.static.flickr.com/129/422780158_71603f2f66_o.jpg

Exciting stuff, huh?
http://farm1.static.flickr.com/167/422780303_1b7ad4fc5d.jpg


I regret having not stripped the old paint off:
http://farm1.static.flickr.com/62/422780346_eb882967ae_o.jpg

[Randy]

Some more pictures.

New Hardware (boo, the old peeling paint looks bad at 3", haha):
http://farm1.static.flickr.com/148/422780480_3d3e1dce4b_o.jpg


P&Cs, lifters, flywheel, stuff (we aren't using those pushrod seals):
http://farm1.static.flickr.com/116/422780577_cbca2cd13d_b.jpg



Painted stuff:
http://farm1.static.flickr.com/130/422780662_400160bdcd_b.jpg


A useless measurement, checking the deck height to the bottom of the dish - 116 Thousandths:
http://farm1.static.flickr.com/163/422780792_66cde789e1_b.jpg

[Randy]

The last four for the day.

Ah, the real deck height with four 8 thousandths shims - 51 thousandths:
http://farm1.static.flickr.com/60/422781111_dc584aeab4_b.jpg


Looking inside the case:
http://farm1.static.flickr.com/177/422781209_92a6d39876_b.jpg


The pushrod tubes, with viton seals, lubed with silicon paste:
http://farm1.static.flickr.com/187/422781271_cce2d64c5f_b.jpg


Clutch cable pulley:
http://farm1.static.flickr.com/60/422781392_9a319c4329_b.jpg

[gms]

I will be out to inspect your work on Monday

[Randy]

I will be out to inspect your work on Monday


Well, it looks like you'll be out to help me wrap it up on Monday actually. Soren didn't get to the heads today, and I got as far as checking the ring gaps and then installing them on the pistons. He might work on the heads tomorrow, but most likely he'll have them done Monday. It'll go quick from here though.

I tried, god knows I tried.

[addwestern]

Saw this car over the weekend and I must say- it is looking very good. Send me your address so I can get that mirror shipped off to you.

Nate

[Randy]

Made some improvements in the engine bay in preparation for the motor install:

http://farm1.static.flickr.com/186/433126309_0a92cd16b0_b.jpg



http://farm1.static.flickr.com/154/433124316_37a6b35490_b.jpg


http://farm1.static.flickr.com/160/433124450_5e1984afe9_b.jpg

[Randy]

And the rest! This came out pretty good considering the lack of prep work I did:

Glenn painting:

http://farm1.static.flickr.com/165/433124690_c812243cec_b.jpg


http://farm1.static.flickr.com/185/433127071_fbb53f56f1_b.jpg

http://farm1.static.flickr.com/182/433125060_ed753a0f6c_b.jpg

[South Elgin 914]

Glenn is really fast. You can tell by the blurr in the picture.

[gms]

Glenn is really fast. You can tell by the blurr in the picture.

OH YAAAAH :D

[bleyseng]

What is that pile of scrap metal in the background? leftover tube frame cars?:eek:

[Randy]

What is that pile of scrap metal in the background? leftover tube frame cars?:eek:

That's my father's property. Let's just say that he's a pack rat of sorts, but thankfully he's gotten in the clean-up mindset this spring. That pile is for the steel scrappers to come pick up. Last week he just hauled off 600 lbs of lead, 300 lbs of aluminum, and 200+ lbs of other metals.

[Randy]

Glenn and I visited Mark in Napa last week and he passed on this K&N filter intake system. I've cleaned and re-oiled the filter element and it's ready for installation:

http://farm1.static.flickr.com/157/437314802_026e347269.jpg

[Randy]

I spent another few hours cleaning up parts yesterday, including the throttle body and fuel pump. I tore the throttle body down entirely and cleaned out the butterfly shaft and air bypass passage and everything else. After reassembling it I calibrated the TPS. I need to pick up some contact cleaner still, but it's looking great!

I reattached it to the plenum and used a very thin layer of RTV Gasket goo on both sides of the gasket.

http://farm1.static.flickr.com/183/437315024_d2583c1484_b.jpg


http://farm1.static.flickr.com/172/437315663_fd1fdfbf11_b.jpg

http://farm1.static.flickr.com/151/437313832_7780fd99df_b.jpg

http://farm1.static.flickr.com/152/437313626_42c4cc5907_b.jpg

[Randy]

This probably isn't very interesting, but here are some of the cleaning photos. The throttle body can hold a bunch of gunk, so clean 'em out!

http://farm1.static.flickr.com/173/437314051_2d67a461f0_b.jpg


http://farm1.static.flickr.com/146/437314197_6d09239d13_b.jpg


http://farm1.static.flickr.com/149/437314255_eaa5ee606b_b.jpg

http://farm1.static.flickr.com/186/437314335_5fac58f616_b.jpg

[Randy]

I'll sneak in a photo of the engine mount bar, painted, with poly mounts:

http://farm1.static.flickr.com/188/437315583_914b6fff7b_b.jpg

I've heard that SirAndy doesn't like poly, so hush hush! :)

[Randy]

The fuel pump was a dirty mess, and the PO used the wrong style clamps (which ehttp://farm1.static.flickr.com/176/437314184_2312633a84_b.jpg

Cleaned up with new mounts:

http://farm1.static.flickr.com/178/437315307_976318c98c_b.jpg

http://farm1.static.flickr.com/145/437315445_7dc46da96a_b.jpg

[Randy]

Oil pressure relocation line and sender for your amusement. Can't wait to get this and everything else installed:

http://farm1.static.flickr.com/146/437314939_55d0543d03_b.jpg

[Randy]

Didn't take any photos yesterday, but I cleaned and painted all the heater ducting and the two sheet metal plates that cover the push rod tubes (that connect to the heat exchangers and engine). Also cleaned up the fan shroud, found a decent used alternator and bolted that stuff together. I used a wire wheel on the fan shroud and it's shining like chrome at the moment. I wonder how long it will take to oxidize.

Somehow I spent six hours out there. I don't really want to think about how many hours are into this project right now, but it's been fun!

[davep]

I've heard that SirAndy doesn't like poly, so hush hush!
You think thats bad, wait till we tell Cap'n Krusty you used RTV anywhere near an engine.:rolleyes: Very nice work though.

[Randy]

You think thats bad, wait till we tell Cap'n Krusty you used RTV anywhere near an engine.:rolleyes: Very nice work though.

There are only a few places where red RTV gasket sealer is OK (per Soren). But yeah, I hate the stuff.

Thanks!

[Randy]

Soren kicked major but this week and got the rest of the components ready for me so that I could get the majority of the long blocked assembled this afternoon/evening.

Everything is done except for the following:

- Rocker assemblies
- Flywheel bolts (I need to put the shaved bolts in)
- Clutch
- Oil cooler installation
- Oil filter bracket installation

Wow, almost there with the long block. Lots of other things to finish up, but maybe we'll have it done next week.

http://farm1.static.flickr.com/182/440383933_d611c861f3_b.jpg

http://farm1.static.flickr.com/200/440384254_83f0e1e0ce_b.jpg

http://farm1.static.flickr.com/191/440384151_43b60705a2_b.jpg

http://farm1.static.flickr.com/187/440384502_afd99ff6f3_b.jpg

[Randy]

And the rest for the evening and I hope to get this bad boy installed ASAP. I'ze gots to race soon, darn it!

http://farm1.static.flickr.com/168/440384584_79b15607f0_b.jpg

http://farm1.static.flickr.com/168/440384507_8e44e2145c_b.jpg

http://farm1.static.flickr.com/158/440384639_056562116f_b.jpg

[Randy]

Forgot the camera this evening, but here's what I've been up to:

1. Transported the motor to my dad's place (thanks David!)
2. Installed oil cooler
3. Installed oil filter support
4. Installed motor mounts and bar
5. Cleaned and installed cooling shroud
6. Bought refurbed alternator, altered rear plate to clear electrical posts
7. Cleaned and painted alternator's pulley
8. Sand blasted cooling fan, painted steel parts black (like stock)
9. Installed fan
10. Installed oil pressure sender remote oil line
11. Installed ignition coil on tin
12. Installed most of the engine tin, minus front and rear pieces
13. Painted some of the plastic bits with Fusion plastic paint
14. Realized plenum I had already painted had a broken support bracket, so I'm prepping another plenum
15. Installed head temp sensor

Some of the to-dos for tomorrow:

1. Complete rocker assembly and install
2. Assemble clutch
3. Install throttle body on "new" plenum, install that unit on motor
4. Install intake runners (with injectors)
5. Route some of the fuel and vacuum lines
6. Install distributor, route plug wires
7. Install pulley on alternator, install alternator

That's more than enough for tomorrow.

I have a few photos that I took yesterday

Motor, before I removed the old alternator (yuck, look at that junk!):
http://farm1.static.flickr.com/195/444612899_d2e6f91b3a_b.jpg

Oil cooler support brackets. I'm posting this photo because I've seen these missing on some motors:
http://farm1.static.flickr.com/178/444605980_89cf2319a4_b.jpg


Always install this cooling flap, or your poor oil cooler will miss out on all the fun (air):
http://farm1.static.flickr.com/186/444605726_39458334e5_b.jpg

Always remember the seal between the tin and cooler as well!
http://farm1.static.flickr.com/228/444605540_ace5fa7a15_b.jpg

[Randy]

I'm beat, so let me just post a bunch of photos:


http://farm1.static.flickr.com/229/446943329_4370f4fb03_b.jpg


http://farm1.static.flickr.com/225/446937294_1c1e81ea14_b.jpg


http://farm1.static.flickr.com/204/446943659_e4499c7242_b.jpg

http://farm1.static.flickr.com/246/446937902_9e438bcf3a_b.jpg

[Randy]

More more more more more

http://farm1.static.flickr.com/235/447867677_0848e8a04a_b.jpg


http://farm1.static.flickr.com/238/447867909_2f45f739b8_b.jpg

http://farm1.static.flickr.com/197/447864530_ec7aea8367.jpg

http://farm1.static.flickr.com/244/447868279_184ca6b21d_b.jpg

[Randy]

Some more more more more and more!

http://farm1.static.flickr.com/161/447868443_ede36b6358_b.jpg


http://farm1.static.flickr.com/202/447865118_09b5fc6b26_b.jpg

http://farm1.static.flickr.com/209/447868707_cdb4b077b4_b.jpg

http://farm1.static.flickr.com/201/447865520_eb54a19498_b.jpg

[Randy]

More more more more more more more,

http://farm1.static.flickr.com/217/447865784_40a7e16d33_b.jpg


http://farm1.static.flickr.com/203/447869313_bb8ab1bd61_b.jpg


http://farm1.static.flickr.com/174/447865976_71c687c827_b.jpg


http://farm1.static.flickr.com/188/447869605_f41b9e31b2_b.jpg

[Randy]

Looking through my own photos I noticed that I need to route the TPS and temp sensor part of the harness underneath the intake runners. :)

[Dave_Darling]

Early 73 throttle body--just has the simple solid bellcrank on it.

What were you heating up with the torch?

--DD

[Randy]

Early 73 throttle body--just has the simple solid bellcrank on it.

What were you heating up with the torch?

--DD

Yep, I used an early throttle body. Other than the secondary spring that's built into the later models, I think they're the same (right?). I have others, though I'm not sure I have a late style TB on the shelf.

I couldn't find any of my 13 mm connector tubes that allow you to connect the tube coming off the PCV valve to the plastic splitter that attaches to the plenum. I did have some copper tubing that was very close to the right OD, so I heated it up and drove a straight punch down the middle to expand it just enough. I cut off the 1.5 inches or so that I needed using a pipe cutter and it fit like a charm.

[Richard Casto]

Looks really fun! Engine rebuild as "art". ;) I like all of the macro photo work, but in particular I like the shot of the exhaust valve and copper gasket (love the contrast in colors as well as the lighting) as well as the one with the fuel lines, injectors and intake. :)

[Randy]

Thanks Richard! I've always been a macro fan and can't wait until I can afford a nice D200 SLR with a dedicated macro lens w/ light ring. :)

How are your projects coming along?

[Dave_Darling]

Yep, I used an early throttle body. Other than the secondary spring that's built into the later models, I think they're the same (right?).

Yes in some cases. Other later throttle bodies did not have the fitting for the vacuum advance.


I couldn't find any of my 13 mm connector tubes...

Ingenious! :)

--DD

[Randy]

Yes in some cases. Other later throttle bodies did not have the fitting for the vacuum advance.


Ah, right. Well, I'm glad I have that!

I'm in SoCal for a while, so I won't get a chance to wrap up the motor project until next week.

[Richard Casto]

Thanks Richard! I've always been a macro fan and can't wait until I can afford a nice D200 SLR with a dedicated macro lens w/ light ring. :)

How are your projects coming along?

Slow. It seems that work and other stuff has sucked up all of my free time recently.

I grew a beard over the winter as a way to entice me to finish stripping my car down. It is warming up and I still have the beard. :D I hope to block out an entire day this weekend to work on the car. I can say that I did get a lot of my rotisserie welded up in my welding class. So that is going well.

[Randy]

Sylvie and I took off for a week, but we're back and I'm making some progress again.

Here you can see that the motor's off the stand, on the rolling pallet with the transaxle attached.

http://farm1.static.flickr.com/213/463778786_9629507221_b.jpg

My fire extinguisher arrived:

http://farm1.static.flickr.com/208/463782785_3779e5e73f_b.jpg

Fuel pump, some of the fuel line, etc:

http://farm1.static.flickr.com/230/463784802_85a99bb522_b.jpg

[Randy]

Committed myself to getting the motor installed today as well. I was alone though, so I had to get creative with the hoist so I could get the motor assembly off the rolling pallet and onto the tranny jack.

Here's what I came up with:

http://farm1.static.flickr.com/183/464730437_a4a72f4d82_b.jpg

In the air:

http://farm1.static.flickr.com/221/464723918_4cd367a828_b.jpg


Off the hoist, on the jack and just about ready:

http://farm1.static.flickr.com/176/464730681_ba382d369f_b.jpg

Sooooooo very close. Covered the greasy axle halves to keep 'em from scuffing up the shiny parts:

http://farm1.static.flickr.com/179/464730827_3020df7d9a_b.jpg

[Randy]

It's still going to be a few days before I have all the wiring ready to attempt to start the beast. Lots of finish work to do still. I really need to have it running sometime this weekend.

http://farm1.static.flickr.com/194/464731093_5635f16f0a_b.jpg

http://farm1.static.flickr.com/215/464724410_ccfd065213_b.jpg


http://farm1.static.flickr.com/186/464731217_d1714af4aa_b.jpg

[South Elgin 914]

Looking good Randy!

Here is how I installed my motor. I made an engine hanger from a Harbor Freight Load leveler. The center of gravity on a motor / tranny is at the rear of the motor. Hanging directly using a hoist won't work because the trunk in in the way. My hanger get around this problem. It also allows for adjusting the center of gravity so the motor will hang level (or crooked if you want it to).

[grantsfo]

Looking good Randy!

[Randy]

Looking good Randy!

Here is how I installed my motor. I made an engine hanger from a Harbor Freight Load leveler. The center of gravity on a motor / tranny is at the rear of the motor. Hanging directly using a hoist won't work because the trunk in in the way. My hanger get around this problem. It also allows for adjusting the center of gravity so the motor will hang level (or crooked if you want it to).

That's a wild setup! I don't have that type of hoist, so I couldn't use that design. I really like the idea of lifting the motor from the top though! Very cool and thanks for sharing.

[Randy]

From Saturday's work. Only got in three of four hours that day.

Finished:

- Exhaust
- CVs attached
- Swepco in gearbox
- More wiring, including relay board
- Stuff (everything is starting to blur together

http://farm1.static.flickr.com/182/468007877_c3716bc117_b.jpg


http://farm1.static.flickr.com/202/467996896_f8ee3aef0f_b.jpg



http://farm1.static.flickr.com/211/468008163_8bf9a62427_b.jpg



http://farm1.static.flickr.com/170/467997124_1490b1c880_b.jpg

[Randy]

Here are some more photos from yesterday:

Tightening up the exhaust muffler bolts at the rear bracket:

http://farm1.static.flickr.com/229/467997212_9d0cb88090.jpg


http://farm1.static.flickr.com/198/467997348_1b517a9793_b.jpg


Can you figure out this one?

http://farm1.static.flickr.com/168/467997440_0628794425_b.jpg


http://farm1.static.flickr.com/212/467997608_85428cbfaa_b.jpg

[Randy]

Two more from Saturday's work, and then it's on to today:

http://farm1.static.flickr.com/228/468009205_a86dac26ec_b.jpg


and

My ugly tuna can:

http://farm1.static.flickr.com/192/467998072_be8e6564df_o.jpg

[Randy]

I spent 9.5 hours on the car today and managed to start the engine for the first time! Hooray! Sounds great (as in mechanically sound), but something's wrong with the FI as it only stays running if you pump the throttle. The motor dies if you try to hold the throttle open, so I need to do some research and see what's going on there. Oh, there's a small oil leak, perhaps coming from the oil cooler area, but I won't know for sure until I've had a chance to run the motor longer than the 3-4 minutes I got out of it tonight.

Not finished entirely, but good enough for a test fire:

http://farm1.static.flickr.com/169/469587056_93b834c268.jpg


Oil pressure gauge sending unit with my custom bracket:

http://farm1.static.flickr.com/193/469587136_27e2d6cc79.jpg

http://farm1.static.flickr.com/176/469587296_fea03346f4_b.jpg


http://farm1.static.flickr.com/173/469603581_4fb5aac794_b.jpg

[Randy]

Here are a few more to wrap up tonight's set:

http://farm1.static.flickr.com/195/469587646_a820354eb2_b.jpg

http://farm1.static.flickr.com/180/469603775_bcd136cc7d_o.jpg


Temporary mount for oil pressure gauge while I test started the motor:
http://farm1.static.flickr.com/208/469587834_494b68259b_b.jpg


How I was seeing the world after a 9+ hour day working on the 914. God, I can't wait until I have a free weekend again!

http://farm1.static.flickr.com/229/469604113_c764caac33_b.jpg

[Dave_Darling]

Can you figure out this one?

Yes, but it's a little obvious--considering the pic right before it. ;)


BTW, a couple of questions:
- Why is the thermostat cable going through one of the holes in where the bottom sheet metal should bolt on? Is it just to keep it out of the way?
- Why is the washer with a tab on the outside of the clutch pulley wheel housing, and not inside the housing with the tab sticking through the hole in the side of the housing?

--DD

[Randy]

Yes, but it's a little obvious--considering the pic right before it. ;)


BTW, a couple of questions:
- Why is the thermostat cable going through one of the holes in where the bottom sheet metal should bolt on? Is it just to keep it out of the way?
- Why is the washer with a tab on the outside of the clutch pulley wheel housing, and not inside the housing with the tab sticking through the hole in the side of the housing?

--DD

Hi Dave,

The thermostat wire was temporarily to keep it out of the way like you thought. :) That's already been changed and will get hooked up the gauge today or tomorrow. The washer on the clutch wheel housing goes on the outside and then wraps around and catches the hole on other side. That's the way I've always seen it (as I can recall) and it's holding the cable very firmly in place. I can take a photo from the other side if that'll help. You can see the tab poking through in that photo above.

:)

[gms]

BTW, a couple of questions:
- Why is the washer with a tab on the outside of the clutch pulley wheel housing, and not inside the housing with the tab sticking through the hole in the side of the housing?

--DD
I have always done it the way Randy did it ???

[Randy]

I have always done it the way Randy did it ???

Yep, that's the orientation I'm using.

[bleyseng]

Where is the missing rubber clutch cable bellows?:eek:

[Randy]

Where is the missing rubber clutch cable bellows?:eek:

I didn't have one that wasn't torn up. I really do need one though! Are they still available?

[Randy]

I ditched the MPS I was using and installed a 43 that I had on the shelf and the car runs and idles. The PO (of the MPS) adjusted it for his motor (which wasn't stock either), but I don't know exactly what he did beyond turning the screw.

I adjusted the timing per the Haynes manual, and it seems too retarded. I stopped on my test run and gave it some more advance it pulls pretty hard nearly to redline. Though it seems like it's still running a little lean at higher RPMs. I'm going to check the fuel pressure tomorrow and will likely up it a few pounds.

I'd love to learn more about putting a resistor (fixed or a pot) inline on the TPS and perhaps on the head sensor as well. I probably need to fidget with the MPS a bit more as well.

Tomorrow I'll adjust the valves for the first time since starting the motor, dump the oil and will also hook up my VDO CHT and oil temp gauges. It's too scary trying to tune this thing without having grips on the basic temps.

More soon!

[Paul Naberhaus]

Randy,
Are you going to put some white grease around that pulley wheel?!

[Randy]

Randy,
Are you going to put some white grease around that pulley wheel?!

Wow, you noticed!

No, I don't think that I am. I thought about it, and then just greased the race that the wheel spins on. The wheel is made out of soft plastic, and there really isn't any friction between the wheel and the cable (as in, the cable doesn't slide on the pulley - it rides). So I don't see how grease would help. Grease does collect small rocks, twigs and crud from the road though.

What do you think?

[Paul Naberhaus]

Randy,
Back in 1976 (yeah, I know, that was along time ago), in effort to keep the bottom of the car as clean as possible (the damned Garvey syndrome), I cleaned all the grease and crud off of that plastic wheel, making it real "purdy" back there. Not long after that, my clutch cable frayed and broke back there. :( Hmmmm. So I ordered 2 cables from Stoddard, and replaced the one that broke. After getting that back on, I applied liberal amounts of white lithium grease around the bolt that holds the pulley on AND around the groove of the pulley wheel, encasing the cable in white grease. Every year thereafter, I clean off the old grease, run a pipe cleaner around the pulley wheel area, and replace with fresh grease. Remember, that's been 30+ years now. I still have the second cable as a spare. Garvey doesn't subscribe to my maintenance, keeping his clean, but then again, ask him how many miles he's driven his car in the last 10-15 years.
I'd put grease on it.

[Dave_Darling]

The washer on the clutch wheel housing goes on the outside and then wraps around and catches the hole on other side. That's the way I've always seen it (as I can recall) and it's holding the cable very firmly in place.

Innarestin. Mine was on the inside of the housing, with the tab poking through the hole and bent to keep it in place. I never questioned it, just put it back the same way each time. I guess I assumed that it was kind of like the nut that holds the throttle cable sheath onto the bracket on the manifold.

Next time I mess with the cable, I should try putting it on the outside.

--DD

[Randy]

The car is running fantastic, took a quick adjustment of the timing and MPS to get things 90% in order.

I'm headed out the door right now, in the 914, to take it up to Thunderhill for my first track event.

For my records -

Current mileage = 66422, adjusted valves again and changed oil 50 miles ago.

Lots of pictures and some video when I get back, or maybe even from the hotel room.

Cheers,