Running Progress Report

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  • #233782
    rockyx
    Participant

    @rockyx

    I thought I would consolidate the record of my restoration for both my benefit and (maybe) others here in the project section.

    Since I’ve already posted on several items I decided it would be easier to just add the link to those threads and then use this thread for all updates moving forward.

    What I started with..

    https://tdreplica.com/forums/topic/the-fun-has-started/

    Disassembly started…

    https://tdreplica.com/forums/topic/disassembly-has-begun/

    Body is off….

    https://tdreplica.com/forums/topic/got-the-body-off/

    Identifying the transmission

    https://tdreplica.com/forums/topic/what-transmissin-is-this/

    Prepping for the floor pans

    https://tdreplica.com/forums/topic/restoratin-progress-a-little/

    Replaced the fuel line

    https://tdreplica.com/forums/topic/replaced-fuel-line/

    Frame head replaced

    https://tdreplica.com/forums/topic/replaced-frame-head/

    Floor pans replaced

    https://tdreplica.com/forums/topic/floor-pans-are-installed/

    Front assembly removal and frame repair

    https://tdreplica.com/forums/topic/frnt-suspensin-apart/

    Front assembly together and chassis primed

    https://tdreplica.com/forums/topic/more-progress/

    Torsion bar removal.. (part of another thread)

    https://tdreplica.com/forums/topic/need-advice-n-ride-height/
    PMOSSBERG2012-02-21 13:05:38

    #247338
    rockyx
    Participant

    @rockyx

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    Hey guys, I haven’t posted for a while
    but I’ve been plugging away and wanted to post a few pictures of how things are
    moving along.

    Following the suggestion of several posts
    I made sure I purchased the OEM replacement bushings for my sway bar and used
    the “clamp and vice grip” approach to install them.  Adding a little grease helped everything go
    together fairly easily.  The process is
    simple.  Tighten the clamp, then tighten
    the vice grips..repeat until you can start sliding the locking clamp.  Then just tap it on with a hammer.

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    Along the way I tore apart, inspected,
    and rebuilt the steering box.  It was in
    very good condition but it took me a while to find the right grease.  I’m not sure I found exactly what was in
    there before but I went with the recommendation from many folks from this site
    and Samba and filled it with Lubriplate 105.


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    I also rebuilt the master cylinder and
    replaced all the brake lines.  I will be replacing
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    I went ahead and removed the back drum as
    well and decided to see what kind of effort they were going to be and that was
    another story.  I’ve never seen anything
    like this. Oddly enough, the drum is still smooth.  If there’s enough metal left I’ll turn them
    down and reused them.



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    Before I pulled the back brakes I dropped
    the infamous automatic tranny.  Pretty
    simple…4 bolts in front and 2 in back. 
    Fluid was nice and red but I’ll take a peek inside anyway and make sure
    the gears are in good order and replace any gaskets and seal to ensure I have
    no leaks when we hit the road.



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    Before
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    Every thread and video I saw talked about
    “tapping” the back of the CV joint and it will “pop right
    off”.  Right!  I tapped until I was afraid I was going to
    break something.  So I decided to see if
    I could take it apart without removing it completely from the axle…since I
    couldn’t. 

    The joints and ball bearings looked
    really good.  So good, I think they’ve
    been replaced before.  That was a good
    thing.  Now I just had to reassemble them
    with the center still on the axle.  Seems
    you can take it apart while it’s on the axle but you cannot put it back
    together. 


    I spent several hours across several days
    trying to put it back together while on the axle.  It just couldn’t be done.  So I figured since it looked like I was going
    to have to buy a complete axle with CV joints to get it all back together I
    might as well try the bigger hammer approach. 
    I must have had a lot of anger built up toward those dang axles cuz
    after some mighty “John Henry” blows it finally came apart.


    I will be repainting the axle and
    replacing the boots but the CV joints will just get a new bed of grease on go
    back to work for another, hopefully, 60k miles.

    I’ve also painted the rest of the chassis
    with Eastwood’s Rust Encapsulator.  I’ll
    post pics of that later.

    Currently I’m working on punching out one
    of the rear stub axles.  Driver’s side
    slid right out.  The passenger side isn’t
    budging. I’m drowning it with PB Blaster and will try coaxing it out again
    tomorrow.  Hopefully I’ll have some
    positive news about my progress.

    A lot of other little things are taking
    place as well but I’ll detail those out in a later post.

    #247339
    bdriver
    Participant

    @bdriver

     

    VW specified a really sticky black lube for the CV joints. Us the right stuff or you will shorten their life.

    Wear latex gloves. It’s really hard to remove from anything it touches. 

     

    #247340
    newkitman
    Participant

    @newkitman

    When I ordered the CV joint kits for my Ghia each CV joint box came with the CV joint grease in the box. 4 CV joints; 4 tubes of CV joint grease. And like BDriver says…wear rubber gloves and expect to get really dirty. Its a dirty job but sopmebody’s gotta do it!  Be patient and it’ll go like……greased CV joints!  newkitman40853.6564236111

    Allen Caron
    VW based 53MGTD - "MoneyPenny"
    "If one thing matters, everything matters" - from the book The Shack

    #247341
    edsnova
    Participant

    @edsnova

    Beautiful pics of hard work, well done. I feel like I’m learning a lot just watching and reading. Thanks!

    #247342
    rockyx
    Participant

    @rockyx

    Stub axle finally removed.  After several days of spraying PB blaster I took my soft sledge and put it up against the axle and then beat the snot out of it with my 2 1/2 lb sledge.  It finally gave up and came loose.

    I forgot to take before pics but the parts were just as cruddy as the CV joint and brakes.  Interesting though, there was no grit in the grease.  That was good news.

    I cleaned everything up and will inspect it closely later this week.  Had to run off to meet a friend and didn’t get finished.

    #247343
    rockyx
    Participant

    @rockyx

    I’ve finished the front and rear brakes and suspension.  Here are a few pictures of the progress.

    I cleaned all the old grease out and repacked everything so it’s good to go for a few thousand miles.

    Here’s the rear axle ready to start rebuilding.

    Cleaned and primed the rear back plate

    Rear brakes assembled.  I replaced the pads, cyclinder, and star adjusters.  Everything else I cleaned up, inspected, and reused.

    Finally closed up and ready to roll.

    With new shocks and brake lines and hoses the chassis is primed and ready to go.

    I still have to undercoat the bottom and seal everything up to prepare for the body but for now we move on to the tranny and engine

    #247344
    schu
    Participant

    @schu

    Looking nice – looks like you are hitting it hard!

    #247345
    rockyx
    Participant

    @rockyx

    Well between travel for work and the holidays I haven’t had much concentrated time to work on the car.  But I’ve pieced together a few hours across the past several weeks and then took advantage of having the week off between Christmas and New Years. 

    Now the chassis is completely done.  I cut out a piece of metal to fill in where we cut out rust and my son welded it in.

    Once it was welded in I sealed the floor pan, primed it with rust encapsulator, and then undercoated.

    Then I put on the wheels and rolled it out into the sun for the first time since I brought it home.  MAJOR MILESTONE.

    Now on to the transmission.  After lots of 2nd guessing about rebuilding it myself I finally decided to dive in….after I found vintage VW transmission shop in town.

    I tore it down in sections.  First I pulled the differential out of the bell housing.  Everything was nice and clean with no marks, scars or crud.  I could turn the gears easily with my hand.  On top of that the fluid was a nice red color with no shavings.  It was obvious that someone had rebuilt it not too long ago.  But I decided to move ahead just to make sure everything was in good working order.

    Clean, clean, clean….And then, the fruit of my efforts was rewarded.  I found, hidden in the bowels of the case, a broken clip.  If I read my manual correctly, this broken part would have kept me from ever getting out of 1st gear.

    Ran to Ace hardware and got another one and started putting it all back together.  But not before some exterior clean up and some fresh paint.

    Hopefully, I’ll have it all assembled tomorrow and ready to mount on the chassis.

    #247346
    edsnova
    Participant

    @edsnova

    wow. Impressive work. I would totally have stopped & put the transmission back together after finding clean fluid. Then when it didn’t work later I’d think that was an error in my reassembly.

    You, on the other hand, are a real mechanic.

    #247347
    texag71
    Participant

    @texag71

    I’ll second Ed’s assessment. In fact, I’ll put your rebuild right up there with Calafer’s — just awe-inspiring.  

    1981 Lafer TI
    1600 cc Type 1 engine

    #247348
    rockyx
    Participant

    @rockyx

    And there it is!

    You guys are more than kind with your compliments.  But I think I’m driven more by obsessiveness, fear, and paranoia more than anything else.  None the less, I’m really enjoying myself and the time with my kids.

    At least now, if it breaks down during my route 66 trip I’ll only have myself to blame.

    Now…on to the engine.

    #247349
    schu
    Participant

    @schu

    Great job – I would love to do a Rt 66 trip myself – it is on my bucket list

    #247350
    bdriver
    Participant

    @bdriver

     

    Have you considered putting another chassis under the TD?

    This one is too pretty to cover up.

    Besides, an original VW slush box has to be the rarest transmission on the block.

    #247351
    rockyx
    Participant

    @rockyx

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    Work on the engine has started.  My plan is to tear it down, ensure the core
    is solid and then rebuild it with 1600 jugs. 

    I am researching the heads to make sure
    they’re the right compression for the larger piston.  The engine number indicates I have a 1300 but
    as you can see it is a dual port engine. 
    The number on the heads seems to indicate they are from a 71 to 73 1600
    motor.  Plus, the valve covers have been
    modified to be bolt on.  All this, and
    some other evidence makes me think I’m working on a rebuilt engine.  Now I just need to find out how big and
    how new.

    So far I’ve pulled off the oil cooler
    shroud, engine tin, carb and one valve cover. 
     Overall the shroud is in good
    shape but some of the linkage needs to be refurbished.

     



    The engine is pretty dirty on the outside
    (even had to scrape off a couple wasp nests) but the tell is in the creamy
    center filling.  So we’ll see.

    First I had to pull the gland nut.  540lbs torque….really!?!  You can see from the bent angle iron that it took more than one shot.

     

    The I got down to business breaking it down.  The reason I started on the floor was that I was waiting on my vw engine stand yolk from Kevin Kraum on the Samba website.





    I got the Bug Me video on engine rebuilt
    and it is awesome.  Literally step by
    step so I’m pretty confident I can get life back into this thing…assuming no
    interior damage.

    My daughter is coming over tonight to
    help me break down the rest of it so hopefully we’ll have more pics by the
    weekend.

    While I’ve been waiting on the engine
    build I started working on some of the body restoration.  One thing I wanted to do was paint my
    headlight cone to match, what will be, black fenders.  A little browsing on the internet and I
    decided to try it myself.

    I started with the chrome finish, roughed
    it up, applied adhesion promoter, painted Rustoleum enamel black, and then clear
    coated.  Then did the wet sanding and
    started polishing.  I was astounded with
    the results.  It’s a lot of work so I’m
    not sure how much more I’ll do but it was a great learning experience.



    #247352
    mike-n-scarlett
    Participant

    @mike-n-scarlett

    Rocky I have been enjoying your restoration since the beginning.

    I like how you have been giving a narration of the process along with the photos.

    I wish I had  headlight mounting brackets like you have on my CMC/FF. They are much nicer than the brackets on mine.

    Keep up the good work and the progress reports.

    #247353
    pmossberg
    Keymaster

    @pmossberg

    Info on the original style headlamp brackets is here:

    https://tdreplica.com/forum/forum_posts.asp?TID=3183&amp; PN=1&TPN=1

    PMOSSBERG40924.5637384259

    Paul Mossberg
    Former Owner of a 1981 Classic Roadsters Ltd. Duchess (VW)
    2005 Intermeccanica Roadster

    If you own a TDr and are not in the Registry, please go to https://tdreplica.com/forums/topic/mg-td-replica-registry/ and register (you need to copy and paste the link)

    #247354
    mike-n-scarlett
    Participant

    @mike-n-scarlett

    Thanks for the link Paul. I would love to have some, but at $240.00 per side I think I will just keep what I have. They arent as pretty, but at least they hold my head light buckets up. I might keep an eye on ebay for some that need refurbishing.

    #247355
    ray10
    Participant

    @ray10

     

    I took mine off the Dutch?s plus the door hinges and misc. to the localHigh school and had them powder coated (black). The total cost 40.00 Plus they got the experience. I got an estimate from a body shop it would Have cost me 150.00

    TDREPLICA Map

    http://www.arcgis.com/home/webmap/viewer.html?webmap=7f9174ad614e43b680deba085b0abf48

    #247356
    rockyx
    Participant

    @rockyx

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    The engine tear down is complete. 

    And, I’m sad to say, it was nowhere near in as
    good condition as the tranny.  As a
    matter of fact, based on the inspection guidelines from the “bug me”
    video I’m going to have to replace everything except the case and the oil pump.

    It all came apart without incident.  I struggled a little with the crank pulley
    but once I grabbed the wheel puller it came right off.  Although I did have to finagle the bolts to
    get a good grip.

    I was hoping the rusty jugs were not an
    indicator of the condition of the inside of the engine….but they were. 

    The good news is that I was able to
    confirm that it has indeed been rebuilt to a 1600 with the proper heads.  But that’s where the joy ended.

    The pistons aren’t worth saving and while
    the rods were nice and tight with no play the bearings were showing wear.  One was down to the brass.  It’s hard to tell in the picture but the
    shaded part in the back is all copper color.

    Then, as you can see in the picture, the oil channel on
    the main outside bearing was so worn you could feel the indent in the metal.

    The cam shaft was a little better but not
    by much.  Again, the bearings were worn
    down and the bearing seat was rough and worn as well.

    I’ve found a couple of places in town that can line bore the case and several online supply stores that can provide the rebuild kit at a reasonable price.

    I thought about just buying a new engine but even with replacing all the parts I’m spending half or less of what a replacement long block would be.  Plus, I get the experience of doing it myself. 

    So this sets me back about 3 weeks which is frustrating but it will all be a great memory when me and the kids are done.

    Here are the pics.

    I’m hoping I can refurbish the heads and at least reuse them.  But everything else is scrap metal.    Oh well.  It’s the journey…right?

    #247357
    edsnova
    Participant

    @edsnova

    Good eye, mate! I guess a rebuildable motor isn’t nearly as good as a rebuilt motor, but like you said–you do have some usable parts there. And you obviously gots the skilz you need to get ‘er back together.

    So I have a tech question: New crank, or not? I ask because of the wear pattern on your mains. Do you under-turn the main bearing journals on these, bore the case and get fatter mains, or just go with a new crankshaft?

    edsnova40931.3447685185

    #247358
    rockyx
    Participant

    @rockyx

    Ed,

    I pondered that question for 2 days after my findings.  I finally decided that, for simplicities sake, I’m going with a new crank.

    Matching over sized outside bearings after the case was line bored was all I wanted to deal with. 

    Plus the cost of turning the crank ($50 to $75) and the extra trouble just didn’t seem worth it with the surplus of new reasonably priced parts available online.

    I’ve priced out rebuild kits from several sites and based on the additional cost for a new crankshaft it only makes sense to go new.

    I figure I’ll kick myself down the line if I do anything else.  I mean I’ve already gutted it so this is my chance to do it right.

    #247359
    edsnova
    Participant

    @edsnova

    Wisdom. I’m trying hard to develop that attitude. 

    #247360
    1oldbuzz
    Participant

    @1oldbuzz

    rockyx

    Have the original crank turned.You will sleep better at night.A good german crank,allthough turned/rezised is far stronger and superior to the foriegn cranks on the market.

    There is machinability designed in both the vw case and crank.ONLY take enough material off the case saddles and crank to put everthing back in round/spec.Cranks and cases can be bored/turned several times if done right.Search carfully for a good vw engine shop good work does come at a price.

    #247361
    rockyx
    Participant

    @rockyx

    oldbuzz,

    I absolutely agree.  That’s why I the rebuild kit I am ordering includes a reconditioned OE German crank.  This way, all the parts are made to fit by a single provider.

    Appreciate the guidance and duly noted.

    Thanks

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