Nice job, well done!
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Nice job, well done!
Thanks, Its been a while since ive updated but now we are up to date, work has been keeping me busy and tired. I havent been driving the car much either as so many rattles have risen that it has become a real unpleasant experience to drive the car.
Had another coolant system failure, this time was the worst, the radiator cap failed catastrophically and it wasnt even at 220' yet, I was able to get home after refilling with tap water at a nearby restaurant, once I got home I flushed the whole system and removed the plugs on the engine block to may sure I got that hard water out. Since the Incident a new radiator cap has been installed and is holding great, very little water is being lost out of the overflow.
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To help lift my spirits I did a bit more work on the EFI project, one part I thought I was going to have to fabricate from scratch steel was a elbow to connect the stock air filter to the air flow meter, some fellow DMC owners performing a EFi conversion gave me an idea to use a rubber intake part from a VW rabbit with CIS, after a few junkyard trips I found one in great shape for just $5.
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Its nice to use a OEM quality part that fits great but when its installed it will not be visible. The search for a new W pipe to connect the twin throttles to the air meter continues, and if I find nothing I will have to weld one up.
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Then this last week I had my friend sand blast my dirty corroded valve covers, they came out great.
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While they were off I readjusted the valve lash it was getting a bit loud.
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I thoroughly cleaned the sand off the covers and then gave them two coats of primer, next three heavy coats of VHT Wrinkle Black paint, It actually came out very nice. Sometimes the wrinkles come out splotchy.
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After a night to dry it was time for a test drive, I didnt get far before a large amount of oil began pouring out of the passenger valve cover and onto the exhaust manifold. I took the cover back off tonight and found the issue,
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while the new gasket and sealant was setting I fixed something that has bothered for quite a while the rusty air intake flap, so I polished it.
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Love this pic :)Quote:
Originally Posted by vwdmc16
I have a new parts order coming in from DMCMW, I also had to redo my valve adjustment job, it seems I got a few too tight.
In the meantime there is plenty of labor needed to repair the rattles in the doors that are making me insane. Also got this '06 Kawasaki EX250 for the decent price of free, after an afternoon of cleaning and service, she runs tops! She should save me some gas money to free up more for the Delorean fund.
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I pulled out my Brake master that has been feeling spongy and has begun to loose pressure on me, that wasnt too hard to remove. The brake booster behind it was a lot harder to pull out, It needed a good cleaning and repaint.
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alot of debris and grease in that area
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after 1/2hr of scrubbing it looks better, I wish I had a pressure washer to really get it clean in there.
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New brake MC
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Cleaned and painted booster. I will get some fresh stainless nuts to install these tomorrow too.
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The refreshed booster is back in.
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New stainless nuts.
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Now to bench bleed the master, something that should be done on any master cylinder before installation to ensure there are no bubbles stuck inside. I clamped it in a small drilpress vise, and inserted two rubber lines in the outlets that run back to the reservoir to recycle the fluid, then pump with a screwdriver until the bubbles stop.
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Bolting the MC in is simple, after the lines are back on, bleed each corner of the car and done.
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With some solid brakes I was ready for another long drive, I met up with my friend David and Jon in Fairfield then off to Marin county to meet up with the Nor Cal DMC club for a 50 mile drive on the coast roads.
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Nice meeting :)
Not driving the car much now that I got a new motorcycle and still have un finished projects to do. The other night I felt like working on the car and just had to clean up the cowl intake area at the base of the windshield, it was bothering me alot.
To take out the plastic cover you need to remove the wipers, some screws and the fender have to come loose, but I still saw no way without removing the windshield or the wiper shafts that looked seized in solid, so that wasn't happening. So the next best thing was to remove the plastic in 3 sections so I had to cut it. I also want to add a mesh screen over the fresh air intake to prevent debris from entering.
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With that cleaned I felt compelled to realign my trunk better, so I removed it.
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On close inspection of the hinges, it seems that both had broken, the driver has sheared the pin in two but still was solid. The passenger however was really messed up, only a tiny part of the pin maybe the size of a ball point pen tip was left holding it on. This was very dangerous.
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The pin had rusted solid to the hinge body. NOS hinges are not avalible but new all stainless ones are... for $110 a pair. That too much for my blood, all mine need is new pins.
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Well a simple bit of tapping with a punch and hammer was not getting the pin out, after 20 minutes of attempting to lube and heat the metal it became apparent that I was going to have to drill this out.
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Lots of drilling and banging later the pin was out of both parts.
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One new 3/16" steel rod cut to fit, and tapped in place after I straightened the hinge out from all that hammering. Then the pin is welded so it doesnt walk out.
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With the dead hinge ready for more action I test fit the hood, Ugh pretty bad. The leading edge was about 3/8" too high and nearly 1/2" high in the middle. I removed the hood and was going to lower the hinges, But the four bolts that hold it to the underbody also looked extremely seized in. All sorts of hell would rain if those sheared off.
I had to pull out the headlights just to see those bolts anyways, atleast my headlight brackets are holding up great!
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These just scream " Dont even think of removing us in one piece"
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So instead of moving the hinges down I had to bend them down about 3/8". Time for another test fit, great on the corners but the front center still was about 1/4" higher than the fascia. So I loosed the fascia mounts and pryed them up as much as possible. slots are maxed out now.
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Another test fit, I need more! So I cut some washers into some shims. I inserted them between the fascia's urethane and the mount I pryed earlier. I also pulled the Fascia forward in the center to increase the gap.
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Bingo! some respectable flushness , just need to raise the front part of the fenders but I will leave that for another day.
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Wow, those hinges are scary for sure. Hope the fix holds up for you! The front edge does look better than before though so that's great news.