2002 Touring '74 from Belgium, full restoration project (Lots of pictures)

[D.martijn]

17 hours ago, jgerock said:

Excellent progress!

Thanks, Jim!

[D.martijn]

Finally got the remaining parts painted black. After making a spray booth with some square tubing and plastic foil + a little rack to hang to parts on I got started with painting. Second time using a paint gun, turned out pretty good if I say so myself

 

I'll probably give it a second coat when it's all dry as I laid it not too tick to avoid runners + there are a few small spots that I didn't quite fully cover with paint.

 

 

Radiator, I did not paint the little cooling fins as I still need to bend some of them back into shape. I'll spray these with some heat resistant black paint later on.

 

Air filter housing lid

 

Diff + driveshaft parts

 

Brake booster

 

 

[D.martijn]

After buying another liter of 2k black satin paint we got the second layer on the parts.

There were a few spots that had some overspray so I decided to lightly sand these parts first so I could get a smooth finish when applying the second coat.

 

As far as I can tell it came out very good, especially for only using a (cheap) spray gun for the third time.

 

my brother and I also started disassembling the startmotor for the engine. We'll probably give this only one coat when doing the underside of the air filter housing and lid as I haven't painted those yet.

 

The stator still looked good as does the stator, we'll just give them a clean an reassemble them back after painting the housing.

[D.martijn]

Saturday I gave the parts a second coat, today they were dry so I took the one that were good off the rack.

I painted the cv joint bearing races, the underside of the air filter housing, starter motor and gave the diff another coat. I hope these turn out good as I my paint gun wasn't set correctly in the beginning, the paint went on a little too thick.. We'll see how it turns out.

 

These parts are all finished now:

 

 

 

 

I also took our radiator to a local radiator repair shop as I noticed after painting that there was a little crack right above the drain bolt. The guy said he'll also pressure test the radiator to make sure it's all right. He will bend the little fins also straight as there are a few that are bend inwards.

 

I then order new cv bellows and a new Bosch starter drive/gear (as the bearing on the original one is too far gone) + new brushes for the start motor too

Edited July 24, 2017 by D.martijn

[D.martijn]

Today I got the alternator for the 2002 back assembled together. I got the question from 2002faq member @rapandi if it would be possible to explain how I did this so here it is  

 

I started with mounting the new stator in the rear housing, feeding the wires through it.

 

I then screwed the base plate with diodes? on the housing and bend the wires on to the contacts. the base plates connects the diodes on the housing and the black plate on the rear of the alternator together.

 

Since the original wires for the diodes on the black plate were too far gone, I soldered new wires on them.

 

Then bolting it on the housing. By then I also mounted the brush plate on the housing as the green cable on this also connects to a spade plug on the base plate (where all the wires come together)

 

I then tapped the bearing on the rotor, make sure you don't forget to put the spring washer (pictured after the rotor) between the bearing and housing!

 

After mounting the rotor, the hard part is done. You then just screw on the front housing and mount the fan and pulley.

All done

 

I hope this helps some of you that are also considering refurbing their alternator. If you have any questions, feel free to PM me.

____

 

 

Also got the remaining parts out of our spray booth. Turned out great.

 

 

Edited July 25, 2017 by D.martijn

[Buckeye]

On 7/25/2017 at 8:17 AM, D.martijn said:

I suggest to use Blue Loctite to those countersunk head screws (2) when assembling solenoid switch to Housing Assy Front.

 

 

 

 

[D.martijn]

18 minutes ago, Buckeye said:

 

 

Thanks for the tip! 

[rapandi]

Thanks @D.martijn much appreciated.

[D.martijn]

Haven't done a whole lot this week. I cleaned the Golf mk1's engine compartiment as some oil is leaking from the distrubitor again even though I replaced the o-ring.. 
After finishing the Golf mk1 I got started on painting some of the left over parts.
I still had to paint the startor housing of the starter motor, a few small parts and the radiator & air filter housing.

 

Turned out alright.

 

Here you can see the repair I had done on the radiator, the guy also bent the fins straight.
The radiator will look great once the paint is dry

 

 

I then got started on repairing the water scuttle panel as it's quite rotten..
I started with bending the two flanges and adding the little indentation in it with a chisel. Turned out I got the bends spaced to far apart to it didn't line up all that great.
Since I had spend quite some time already on the panel, I went home.. lol

 

The day after I tried to get the bend right, which I luckily did. Again, hammering the indentation in the panel with a chisel.

 

 

Welded and ground down partially, I still need to fabricate a few other bit's like the oval hole in the middle that's also rotten.

 

Still need to grind down the little weld but all my discs are completely used up. I should buy some new ones.

 

Turned out pretty good, will still need some filler though.
I am considering buying a sheet metal brake to get better 90° bends. I'm now using a big piece of angle iron but from hammering the flat sheet it gets wavy because of the slight stretching when hammering it against the angle iron.. 

 

[Tommy]

On 8/4/2017 at 5:40 PM, D.martijn said:

I am considering buying a sheet metal brake to get better 90° bends. I'm now using a big piece of angle iron but from hammering the flat sheet it gets wavy because of the slight stretching when hammering it against the angle iron..

 

You have great skills. I encourage to invest in tools though you're doing really well with the primitive methods.

[D.martijn]

11 hours ago, Tommy said:

 

You have great skills. I encourage to invest in tools though you're doing really well with the primitive methods.

 

Thanks, Tommy. Yes, just a hammer, a few dollies and a chisel is what I have now as metal working tools.

A shrinker & stretcher are also on my list of tools to buy

[D.martijn]

Haven't done much lately on the 2002 Touring.

Last week I removed the hinges from the chassis. It took quite some heat, penetrating oil and some hammering but finally I got them all out.

 

Still need to clean up the hinge points.

 

I also got a new drive gear for the start motor as the one way bearing on the old one didn't work anymore.

 

I soldered new brushes on as well

 

Today we started on some rust repair on the A pillar.
I started with removing some of the left over pieces on the sill

 

After quite a bit of fiddling and trimming the panel fitted pretty well. but I found that the curves of the replacement panel didn't line up all that good.
So I decided to make a slice on top to get the bend more inboard.

 

I did the same thing on the lower side of the panel.
the left cut was to get the little notch bigger/more defined. and the 2 other ones on the right to get the piece flat against to the original sheet metal.

 

After that we tacked the panel in place and removed the pitted flange in the middle.

I spaced out the plug welds like original and also added the full welds. Turned out great.

 

Picture I took when welding, almost there

 

I got good penetration on the backside of the inner panel

 

All done

 

After a lot of welding, it's mostly finished. I still need to get some new sandpaper belts for my powerfile to get into the little corners.

 

After we were finished with grinding, I sprayed some zincspray to protect the bare metal.

 

 

I also tried to cover the inside where I welded but wasn't able to get to it with the normal spraycan.
I used the plastic spray nozzle/tube from a old can of wax

Edited September 16, 2017 by D.martijn

[D.martijn]

Now that the zinc spray is fully dried up the repair isn't very visible any more. Very please with the outcome.

 

Today I received my new CV boots. After ordering 2 other sets I finally got the right ones.

I didn't want to get a cheap set with regular hose clamps or a set from a brand I had never heard of. I'm not planning on replacing these anytime soon.

I found a set of Spidan boots that fit a Alfa Romeo. a few sites also stated these should fit the BMW E21.

After making sure the dimensions were good, I went ahead and ordered them.

 

Part no, if someone's interested

 

Boot's fitted pretty good

 

I only had time to do one axle this evening. Fitted with the replaced discs. I also added a thin bead of sealant. 

 

[AceAndrew]

Great progress, I enjoyed your alternator and starter rebuilds.

[Buckeye]

4 hours ago, D.martijn said:

 

 

I only had time to do one axle this evening. Fitted with the replaced discs. I also added a thin bead of sealant. 

 

 

Did you buy the discs separately? Can you share part number and where you purchased discs (covers)