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Old 05-18-2022, 08:41 AM   #51
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That spring needs more tie wraps. The thick strong type.
Yessir! I knew I would have to adjust it quite a bit, so once I finish up the brakes, I'll get it set down, adjusted and tie wrapped!
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Old 05-29-2022, 10:48 PM   #52
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Today was pretty great. Started the day getting ready to install my freshly painted rear calipers, rotors and pads. I then realized Napa sold me two driver side calipers... whoops!

With the last four weeks of welding class being open to whatever projects we want, I took the opportunity to build up an exhaust for the car. A new Walker catalytic converter with 2" stock piping, then steps up to 2.25". I used a Totalflow small resonator in place of the stock one, then it goes into a stock turbo under axle pipe. Last two parts are a 2.25" Thrush turbo muffler and out the back with a 3" chrome tip. It was my first time Tig welding tube, so the results were okay, however, it was a blast to build up. I'll have pictures when I'm ready to install it.

I also removed the transmission from the car today in less than 3 hours! It helps that I had it all apart last year, so fasteners came out easy Soon to come is the M46!

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Old 06-04-2022, 08:56 PM   #53
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In welding class today, I used the free period to extend the head rest in my 242. Pretty simple, just recycled a drum brake tool handle (3/8" solid tool steel), cut the head rest pieces with a tubing cutter and then welded in the extension pieces.

Instead of the top of the head restraint being at the base of my skull, its above it now by about an 1-1/2". I thought it would look off with the rods showing above the seat, but it just looks like any car with an extended head rest! I'll just paint the metal and leave it


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Old 06-10-2022, 11:56 PM   #54
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Today was huge for progress! I only had plans to remove the auto shifter, being that the last week and a half has been finals week, so not a ton of energy. Well, I decided to install the flywheel, friction disc and PP.

Then, I just couldn't stop there. Next was getting the car back to 3 pedals. I moved on to getting the trans lifted into the car and mounted. Everything went pretty darn well for being unplanned! I also forgot to get a reverse harness for the M46, but I made my own with GXL 16 ga wire and a couple bullet connectors.



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Old 06-11-2022, 12:33 PM   #55
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Looking good!
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Old 06-12-2022, 09:44 PM   #56
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Today I knocked out some of the smaller tasks of the manual swap. I have an M47 shifter with an M46 knob. There was no wiring, so I made my own little harness, drilled a hole and installed a grommet. Turned out good!


I used STS bronze shifter bushings. Strange to see a "real" shifter in the interior.


I have an OE clutch cable which I used in conjuction with an STS delrin bushing. Got the freeplay set at ~2.5mm.


I also picked up brake fluid and cheap Type F ATF. For the ATF, my plan is to start with the cheap stuff and check the trans for leaks. If the OD doesn't perform well on that, I'll switch to something better.
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Old 06-13-2022, 01:14 AM   #57
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Not a bad plan to use cheap ATF and change it in 1000 miles or so. It's a good douche for an old tranny.
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Old 06-17-2022, 10:02 PM   #58
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New carrier bearing installed. One previously on there was dry and noisy. In order to get the bearing all the way on, I had to press against the flange on the other end. So, I ended up going ahead and replacing the u-joint as well. (FAG bearing, Spicer u-joint).




I noticed that the factory u-joints have the ability to be greased, just remove the grub screw and replace with a grease fitting. The joints in the back half of the 2" replacement shaft I have feel good, just going to give them grease and install.

Next on the list was replacing the vacuum lines. I've been cutting off the cracked portions and reusing for a while, but decided to do the correct thing and replace them. Funny thing, the charcoal canister in the car is a GM product made by Rochester. Pretty sure that's not original.

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Old 06-18-2022, 11:04 PM   #59
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Today was a great day for progress. I started the day by cleaning the garage up and putting all my tools in my chest. Summer break is nice for having extra time and motivation.

I drained the last little bit of fluid from the M46. Plug has some metal filings on it, not too bad. Fluid was still bright red. Very mild "glitter." I then filled it with fresh Type F.


I hooked up the driveshaft, the old bearing carrier bushing was in bad shape. I had a less destroyed OEM piece on hand, so I used that.


I installed the exhaust that I welded in the college class I took. Fitment is actually pretty good for having welded the exhaust away from the car!



I also filled the diff with some high quality synthetic 75w90, and filled the power steering system with Type F. I then started up the car for the first time in a while. Exhaust sounds great! Super mild, but still sporty.

The bleeding of the steering system was interesting. The rack is a used ZF replacement, and when I first started bleeding it by turning the wheel from stop to stop, it started turning all the way to the right on its own. I continued to "excercise" the rack, and eventually it started to act normally. Must have been clogged somewhere. After bleeding it, the atf turned brown. I'm going to drain the system and add an inline filter on the return line.
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Old 06-19-2022, 07:05 PM   #60
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Today I replaced the brake master cylinder and bled the brakes. The old master still had good feel, but I had pressed the brake pedal while it was empty when I was swapping my pedal setup for the M46. Turns out it was starting to leak from the back, anyway.



New master bleed went fine. I only had a partial Dorman bleed kit, so I made do.


I used the Motive power bleeder from IPD. It only took two tries to get the system bled, which is pretty great as the system was pretty much dry. Very pleased with the tool.


I am so close to being able to drive the dang thing. If I didn't have the body work on the rear quarter to do, I could put it on it's wheels now and test drive it.
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Old 06-19-2022, 10:12 PM   #61
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Great progress on the car! I am looking forward to trying out that delrin bushing on the clutch cable.
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Old 06-20-2022, 09:41 PM   #62
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Great progress on the car! I am looking forward to trying out that delrin bushing on the clutch cable.
Thanks Dave! The clutch pedal feels really good with the delrin.

Today I addressed the power steering fluid issue by draining the pump and installing an inline filter. The fluid is still pretty murky, so after I get the car on the road I'll change the fluid every couple hundred miles until I see improvement.



Next, I swapped out the temporary masking tape exhaust "clamp" with a real one I noticed that these stainless band clamps don't seal great on their own. Better than the crush type, but still not perfect. I'll be looking into some sort of fix for this.


Last was removal of the auto trans cooler lines, which I think marks the last part of the auto being removed from the car!
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Old 06-20-2022, 09:52 PM   #63
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You can use some exhaust assembly paste on the inside of the clamps to make them seal really well. There is a Walker version
of those clamps that has the nuts built in. They are sold at Summit racing. Those seal a little better.
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Old 06-20-2022, 10:17 PM   #64
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You can use some exhaust assembly paste on the inside of the clamps to make them seal really well. There is a Walker version
of those clamps that has the nuts built in. They are sold at Summit racing. Those seal a little better.
I completely forgot about the Walker brand ones. I've had those in a Dynomax exhaust system before, they work great.

Any brand of assembly paste you can recommend?
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Old 06-22-2022, 08:50 PM   #65
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I think it was a Permatex brand. You make it wet to activate it. So throwaway gloves are a must.
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Old 06-24-2022, 07:59 PM   #66
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I think it was a Permatex brand. You make it wet to activate it. So throwaway gloves are a must.
Cool, I ordered the Permatex stuff. Going to try that with the clamps I already have.

Nothing super wild today, I decided to switch up my priorities and leave paint for very last on this car. I finished up my welds/ground all of them down and sanded a narrow area around all the spot welds on the replacement quarter. I tried to get a couple of the 2K epoxy spray cans, but the paint store closed right when I got there. So, I had to be brave and try HVLP for the first time. I painted a single coat of OMNI epoxy on the portion I sanded.



The goal was just to cover the areas I worked on so I can put the car back together fully and prioritize the driveability. My current plan is to POR-15 the rocker panels and door wells. I'll probably prime it, but leave the painting up to a shop. This process is not my favorite, so I'll leave the top coat to someone who has patience for it
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Old 06-24-2022, 10:47 PM   #67
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Had more energy this evening, so I set my cam gear back to 0° and checked my valve to cam clearance. I didn't do it when I installed the A cam, but wanted to for peace of mind. One valve was ~.017", the rest were .016, this was done cold. Good enough for me!

Couldn't stop there, so I pulled my very sad LH 2.0 v.1 harness out, this is the OG harness from 1983... I'm done repairing this darn harness! I have an updated LH 2.0 v.2 (heated O2) and I already have the 510 ecu to match in my car.
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Old 06-25-2022, 04:54 PM   #68
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New temp sensor installed, temp gauge is now working again!


Replacement harness is in, and the engine sounds very happy now. Don't know if it was backing off the cam gear or less sketch wires, but it sounds happier.


Next was repairing the tail light harness. I directly wired to the lights several years ago due to the state of the light housings, but I have better condition light housings, so I soldered it all back together again. Also, check out that poor wire that got smashed against the body (was shorting, too!).


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Old 06-25-2022, 08:08 PM   #69
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I replaced my old, sad hood with plenty of dents with ome that is straight and the paint is in OK shape. It has the factory underhood insulator, too, which is pretty neat!




I also installed my new plates/tags and applied seam sealer on the quarter panel.
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Old 06-26-2022, 06:38 PM   #70
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Factory under hood blanket is either turbo or diesel on the old coffin hood. They sag a big so you may want to try and pull it up some.
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Old 07-01-2022, 11:15 PM   #71
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Factory under hood blanket is either turbo or diesel on the old coffin hood. They sag a big so you may want to try and pull it up some.
I'll have to do that at some point, thanks for the tip!

I switched the aftermarket steering joint that came with my replacement rack back to the OE piece that was on my original rack.


I worked hard to get the car together enough to drive it for the first time with the manual. So that meant torquing the suspension once I got it on the ground. I also installed the taillights a couple days ago.

Once I felt everything was ok for a test drive, I went for it! Having replaced the coolant temp sensor recently, there was an air pocket in the system that was causing the engine to get very hot. So I quickly drove back home and got that sorted out. The real test drive went pretty great! R and 1-4 gears are operational, with 1st being a bit noisy for some reason. OD worked the first time I tried it, but failed to work again. I can still hear the solenoid clicking, so not sure on that yet. The trans leaks from the trans to OD bolts, but I don't think it lost enough fluid to cause the OD to be inoperable.




Overall, it was a fantastic experience to FINALLY get to drive the darn thing. The sport springs in the front sit a bit high, I'm hoping they settle a bit. I had to max out my rear BNE spring perches so it doesn't look goofy. The new brakes performed very nicely!
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Old 07-02-2022, 03:45 PM   #72
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Such a good feeling when it's operational. Even if not sorted completely it's great to bring a machine back to life. Let me know when you are ready for one of my B21FT for your turbo swap. LOL. Keep it old school redblock turbo.
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Old 07-02-2022, 11:51 PM   #73
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Such a good feeling when it's operational. Even if not sorted completely it's great to bring a machine back to life. Let me know when you are ready for one of my B21FT for your turbo swap. LOL. Keep it old school redblock turbo.
I agree! Finally it's a driving project instead of a non usable money pit Don't tempt me with Turbos, Dave! Maybe after I finish up the last year of my degree I'll do a proper turbo swap

I worker on the interior today. Trunk is cleaned up and carpet reinstalled.
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Old 07-02-2022, 11:59 PM   #74
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I have two pairs of interior door panels, both in poor shape. I used the two best felt wipers and also brushed some fiberglass resin on the damaged areas. I made some quick and lackluster moisture barriers and installed them behind the panels. Put those on the doors and got the rest of the interior put together.




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Old Yesterday, 11:42 PM   #75
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The M46 has had a fairly bad leak since I filled it. It's coming from between the OD adapter and the trans. After talking with hiperfauto, I went ahead and put sealer on 4 of the 6 bolts (can't get to the top two without removal of the trans). I did them one at a time and torqued to 30 ft. lbs as I went (greenbook spec is 25-35). The rear portion of the transmission has certainly been apart before, and the OD adapter to trans is sealed with RTV. I used my jack to support the trans and slid the crossmember back during the procedure.




One of the lower two bolts that was on there was too long and spaced out with a nut. This may be where the leak was coming from.



Next, I decided to use a product called "glass stripper" on the windshield, which has the consistency of sun screen with baking soda mixed in. The windshield is pretty crappy and pitted, but I am not wanting to spend any more on the body until I am certain the engine and drivetrain are capable and in good enough shape to do what I need them to. Anyway, I used RainX after the stripper and it is good enough for now.




Lastly, I installed my blue center arm rest. Pretty neat little piece!

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