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Old 04-01-2020, 09:56 PM   #26
IansPlatinum
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Started assessing driver's floorboard. Found a hole about the size of a quarter after I started stripping the paint. ****. Now I guess I gotta weld a patch panel into driver's side. Looks nastier underneath.



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Old 04-02-2020, 11:34 AM   #27
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Looking at the undercarriage, you may have more to deal with. I'm not a fan of that black tar that was sprayed by dealers in the 60's and 70's. It didn't always do what it needed to do.
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Old 04-02-2020, 12:33 PM   #28
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Yep, I'm going to have some work to do for sure. I'm not necessarily going for show quality, so whatever keeps the rust at bay works for me.

Plan right now is to get every piece of rust exposed, scraped down, burned out with phosphoric, and then coat with epoxy primer.

There's also rust on the seams that was hiding under the seam sealer. Wondering if I can scrape a bunch away, and then heat the seam up and let the phosphoric acid get pulled in via capillary action. I really don't want to separate the spot welds just to get the rust out.
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Old 04-03-2020, 06:09 AM   #29
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Have fun removing that ****. This floorpan is listed for 240's but fits (with some persuasion) in 72 up: https://raybuck.com/product/1975-93-...n-driver-side/
Since you have a 71, it may not be much help, but you could give it a shot.
It looks to me like after you clean the undercoating you can get the floor braces cleaned with a good wire wheel.
Once you get into it, you'll probably need to remove more than you think to get to good metal.
A spot weld bit drills those out in no time. I also have a Steck panel buster which helped separate the remaining weld. Just don't go thru the brace like I did in a fewspots. Then, if you can weld, plug welds aren't too hard to do. Even I can do them!


Last edited by sksmith; 04-03-2020 at 06:16 AM..
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Old 04-03-2020, 09:38 AM   #30
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Have fun removing that ****
lol thanks


ended up taking apart the blinker stalk, the right blinkers would only come on if you jiggled the stalk vigorously. my god that thing was frustrating to get back together. There's a spring loaded metal cylinder that wants to push the entire assembly apart. It probably bursted out and flew across the kitchen 5 different times.



cleaned the contacts and got it back together, and voila, both blinkers work... but the right blinkers now activate the brights

bent the contact back a bit, and now it works perfectly.

Blinkers, side indicators, tail lights, brake lights, reverse lights, and running lights all work now. Head lights work too, but the driver's side has moisture so I ordered some replacements.

It's amazing how brutal the sun is

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Old 04-03-2020, 08:32 PM   #31
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Decided to investigate the instrument cluster after fuel gauge started acting up despite the new sender. Took it out and noticed something rattling around inside...



Might explain the speedometer not working.

Sure enough, it's the retainer for the rotation of the ribbon speedo.



Went ahead and cleaned up the circuit board too.



Turns out the voltage regulator was flopping around due to broken rubber support. Also the ground wire was barely hanging onto the solder point by 1 or 2 copper strands. Soldered in some new wires.

Rheostat was also not working. Wonder why...



Cleaned up the contacts, now it seems to work!





Verified speedo function as well. Turns out odometer turns too! Guess I got lucky

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Old 04-04-2020, 01:54 AM   #32
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Subscribed This gives me hope for my safari rust bucket
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Old 04-06-2020, 11:33 AM   #33
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New motor mounts and trans mount for rusty. Wonder what year this West German engine mount was installed... needless to say, I think it has done its job. Trans mount was also west german. Unfortunately, the new mounts from VP are made in India. :(

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Old 04-06-2020, 01:09 PM   #34
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India is one of the major rubber tree growing locations in the world; if the mounts are natural rubber then they're being made closer to the source. Maybe modern Indian rubber is better than whatever cold war era W. Germany could get its hands on.
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Old 04-06-2020, 01:51 PM   #35
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Maybe modern Indian rubber is better than whatever cold war era W. Germany could get its hands on.
This wouldn't surprise me in the slightest.
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Old 04-06-2020, 01:59 PM   #36
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You can have the best rubber in the world, but if your process & QC is out of wack then it doesn't matter. My experience is that european-made components tend to by of the highest quality compared to others. who knows, maybe these Indian motor mounts are indeed better. I probably won't be putting more than 1000 miles on the odometer this year, so it doesn't really matter. I just like the country of manufacture to be consistent/original when possible. Like how my new michelin XZX repops are stamped with 'made in serbia'

Who knows, maybe serbian tires are fine, but I'd prefer my michelins to be made in france is all...
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Old 04-06-2020, 04:04 PM   #37
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That's going to raise the engine and trans back to normal heights!
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Old 04-06-2020, 04:06 PM   #38
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Quote:
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That's going to raise the engine and trans back to normal heights!
And apparently take some stress off the gearbox too, less 1st gear whine

Last edited by IansPlatinum; 04-09-2020 at 03:36 PM..
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Old 04-26-2020, 12:54 AM   #39
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Today rusty received 10 gallons of gas only to start spilling it onto the ground



Turns out I didn't quite seat the sender. Once I let the gas clear I reinstalled it and all seems well again

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Old 05-03-2020, 11:32 PM   #40
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Lol

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Old 05-04-2020, 11:27 AM   #41
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That rubber looks like dry cheese. How sketchy was the rear end handling ?
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Old 05-05-2020, 11:58 AM   #42
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That rubber looks like dry cheese. How sketchy was the rear end handling ?
I was able to make out a tiny little number from the remains, which sorta indicates a genuine part.

It was... shifty. The tiny little bit of torque produced by the b20 would very noticeably shift the rear end. Still gotta do the other side.
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Old 05-06-2020, 11:32 PM   #43
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Other side was just as bad.



Genuine 240 TAB tool works nicely for this application



Going in...



lol #2...


Last edited by IansPlatinum; 05-07-2020 at 11:03 AM..
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Old 05-07-2020, 11:59 AM   #44
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Wow, that's not good! That car has been driven at least!
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Old 05-07-2020, 12:06 PM   #45
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Quote:
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Wow, that's not good! That car has been driven at least!
It tracks so straight now with the new bushings. Now the gas pedal does not steer the car
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Old 05-08-2020, 10:56 AM   #46
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Installed an excellent condition 'correct' cluster courtesy of Alschnertz. All I can say is wow!

It fixed my sticky speedo issues as well!



Also in the works is acquiring this horn pad...

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Old 05-09-2020, 04:24 PM   #47
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Today I rebuilt the 12V cigarette lighter socket.

No wonder it wasn't working


Unfortunately it broke during disassembly


This spare socket from an 850 has a contact that looks good


And its a perfect fit!


Fully assembled


And it works! LR tire has a slow leak (probably the inner wheel seam)


Slowly getting there...
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Old 05-10-2020, 04:06 PM   #48
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Incredible progress, looks even better in person than on here. Now that it’s running and driving you’re light years ahead of the rest of TB still on jack stands waiting for the crusher to call. I can’t wait to see this driving around town!
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Old 05-10-2020, 07:37 PM   #49
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Looks like a nice wagon. Keep up the good work!
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Old 05-12-2020, 06:40 AM   #50
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Well done! Nice to see your progress!
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