The Restoration of #1768

[Domi]

About your rust problem on the roof, Ed from DeLorean Europe has the solution:
http://www.delorean.eu/catalog/produ...8003&cPath=167
It is all stainless.
Nevertheless, it is a bit expensive...

[vwdmc16]

Oh yes ive drooled over that a few times, Quite out of my budget and requirements honestly. My original box just has a bit of surface rust flakes that were vacuumed away, Now that the car is in dry and sunny California I doubt major rust repair will be required up there for another 30 years.

[vwdmc16]

May 14



I finished up the roof after cleaned out all the rust flakes in the roof which weren't as bad as I thought, But to do so I had to disconnect the 4 large plugs in the roof to get access. After plugging them back together none of my door electrics worked, Ah shit. After tugging and twisting wires I could get the mirrors, the windows or the locks to work but never all three. after an hour of mostly cursing and taking the plugs apart and cleaning the terminals everything worked. Will they continue to work after the next pothole? who knows.


Last night I started on something more productive. More head way on the EFI conversion





This 1/2" aluminum plate is the beginning of my new dual throttle body adapters. They will connect the Volvo 740 16V throttle bodys to the DMC intake. They are relatively easy to build.




Three of the TB holes are 6mm and are tapped into the adapter. The upper Left one has to go through the plate and into the manifold so it will be a m8 bolt.




The other M8 bolt that threads into the manifold has to sit counter sunk in the adapter so the TB can sit over it.




Now the adapters need cleaning up and some more trimming so they look good. But they bolt up nice.






Sadly the Volvo Tb is not symmetrical so I can't just make a mirror image copy of this right hand adapter for the left side. Also the TB will interfere with the rubber hose coming out of the thermostat, I will have to modify the thermostat housing to get the right clearance.

[vwdmc16]

May 15

Now since NOBODY (that I can find) sells M7 bolts in stainless with a Allen head, I have to drill the holes out so I can use M8 bolts. The stainless Allen head is going to be a new theme to the engine, you know because it classes it up.
I finished tapping the five holes to M8, I had to use the 3/8 ratchet attachment at there was no space for a T handle.




The same for drilling it out, had to use a ratchet as my drill wont fit between the engine and bumper.



But finally bolted on with the proper stainless M8 bolts.





For now its back to stock. If I build my new throttle linkage and new W Pipe to connect the two new bodies with the K jet plenum. I could still run the factory injection until I get my fuel rails done and wiring finished. Also this is the first time ive ever bolted my air filter down, ive never felt comfortable enough to have it not lift lift off by hand in case I needed to manually prime the injectors ( i've had too many PPR o-ring failures...).

[DMC5180]

Did you ever consider just one TB mounted to a Modified W-pipe with the throat opening facing level forward?

[Bitsyncmaster]

May 15

Now since NOBODY (that I can find) sells M7 bolts in stainless with a Allen head, I have to drill the holes out so I can use M8 bolts. The stainless Allen head is going to be a new theme to the engine, you know because it classes it up.
I finished tapping the five holes to M8, I had to use the 3/8 ratchet attachment at there was no space for a T handle.

That's what I did. You should also do that long bolt holding the "w" pipe to the throttle body.

[Spittybug]

AWESOME.

I was looking to find a good little throttle body that would fit on the end of the manifold like that. Check out the EFI subforum and specifically the threads on stock conversion to EFI. We've already got the injector/rail/hold down bracket figured out. Your throttle body mod is what I was trying to do for "stage II EFI"; eliminate the stock air intake. Speaking of which, how do you plan to plumb air to these guys? Also, being dual, how do you plan on joining their linkages?

And here's a random thought.... I haven't looked at my stock intake manifold to confirm, but what if you reversed it 180* and put the throttle bodies towards the firewall? I *think* it is symmetrical and since you will no longer have the fuel distributor or air intake they won't get in the way. The dizzy may be in the way come to think of it.... just brainstorming here.

I've been trying to see if I could find a "fly by wire" throttle body so that there would be no need for linkages between the two. I don't know what kind of electronics they use and then there would be a new gas peddle required... but how cool would that be?

[vwdmc16]

I always thought while not necessary and more complicated two TB's would look better, I have a few options to connect them together and im thinking ill go with a new throttle shaft mounted below the bodies with individual connecting rods to each arm, these will use stock Volvo ball and socket joints to help maintain the OEM look. Owen, that is another idea to flip the manifold 180' Ive not really thought of doing that as there would be a void where the stock w pipe was and it might look strange, a simple aluminum cover could solve that like the throttle spool icing recall shield does. My next fabrication hurdle will be the fuel rail mounting, maybe Ill take some ideas from your design.

As for Throttle by wire, I still have not come across any TB that is very small with the built in motor and gear drive. This is conversion will have a period theme to it so electronic throttles would look out of place.

[vwdmc16]

June 8

New package from DMCH:




Lots of goodies!: oil pan and timing cover gaskets, new keyless entry system, fuel, oil and air filter, o rings, clips for the lower engine cover and fuel hoses.



Jon came over again to help with electrical work.



He fixed more wires, sorted out alot of relays that were out of proper order, and wired in my dome light delay module.




Meanwhile I installed some other new parts like the fuel and air filter, I was hoping that would help cure my off idle stumble I get when leaving stop lights sometimes, but alas it didnt help.





With my seats out I could repair the seat rails that were very difficult to adjust. After a good cleaning I punched out 4 broken, stripped or bent mounting studs and welded in new M8 bolts. then a new paint job and greasing.







Test fit, all good!




And a picture of a duck that wandered in my garage.

[Rhsxo]

And a picture of a duck that wandered in my garage.

That was random. lol

Looks like even more progress on an already outstanding car. Keep it up!