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73Tii Resto Build Thread: Barnfind in my own Garage


JsnPpp

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Despite the lack of posts I've been busy on the car. Huge slow down as I clean inner fender wells, inside floor and add a metal patch on the transmission tunnel from where the transmission mount was shifted. 

 

And a few other things. The rear seat support was bent over years of removing the seat. To repair I clamped a heavy metal block under it and then tapped the bent metal down.

IMG_0570.thumb.jpeg.0191b31b2b3006765c2971592699294e.jpeg

 

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This was odd - there are numbers stamped into the top.

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The drivers fender cleaned up well. I still need to ospho, epoxy, etc..

 

 

IMG_0588.thumb.jpeg.cca254d833a5e0e4bf1048fd0320a2e0.jpeg

 

IMG_0590.thumb.jpeg.92ca40e4230b7795524fabde047e6355.jpeg

 

Can't wait to epoxy prime and then replace the seam sealer as needed. I'll also put between fender and frame.

IMG_0595.thumb.jpeg.ed9d12aeb5c3e2bfa38b3329b905eb08.jpeg

 

When I removed the drivers door I noticed one was bent slightly. I used a dolly and a ball joint separator to straighten it. Worked great.

IMG_0596.thumb.jpeg.540c748b5fbd2ffe658649829d0fbbe7.jpeg

 

Too many hours cleaning the bottom of the car. I still need to wipe wax and grease remover, but the big stuff is gone.

IMG_0589.thumb.jpeg.040fbfa4afacf329b4ed1bd5af3fdd29.jpeg

 

Also started cleaning the engine. Once I have finished the bit of work I am doing (floor pan, door jams, fender wells), I will pivot to the engine, get it resealed, etc. (everything new), refresh the front suspension and reinstall. Gets it out of the garage. The plan is by Dec 31.

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More tomorrow!

 

Edited by JsnPpp
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1973 2002tii (2764167), Baikal, Rebuild blog here!

In the past: Verona H&B 1973 2002tii (2762913); Malaga 1975 2002; White 1975 2002

--> Blog: Repro tii cold start relay;   + --> Need an Alpina A4 tuning guide? PM me!

 

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"tomorrow" is relative of course. 👍

 

Good progress, just slow. I feel I turned a corner. Wrapping up the passenger floor, repaired rust in the corner, and patched a hole made when Schatz and Krum shifted the transmission mounts for the 5 spd OD. Cleaning up the nose patch too.

 

Ideally this weekend I epoxy prime everything I've been working on, seam seal where needed and then base coat. None of what I'm working on is highly visible, other than the nose.

 

Once that is done I can finally move to the front suspension and engine. Can't wait.

 

Passenger side floor, can just see the patch up on the tunnel.  Overall the floor is in nice condition, some water sat for a bit but all strong and clean. I need to epoxy prime it and then a very light base coat, like OE.

IMG_0605.thumb.jpeg.c2a532f67c79eba734d6e4bc076b4868.jpeg

 

Here is an older photo of the patch. It's been cleaned up considerably.

IMG_0602.thumb.jpeg.66783482c5aafb6bb358f240119b76b2.jpeg

 

Roughed in nose patch. Cleaned up well, need a newer photo. I will put a light skim of filler or glaze to smooth it out. I pre-painted the backside before I welded it in, but need to shoot some primer as a top coat to the welds, etc. Took time to clean it.

IMG_0610.jpeg.df074082f191f254cce5a60a51ace762.jpeg

 

 

As it stands now. Its a bit of a mess but better than it looks.

IMG_0623.thumb.jpeg.834cd9b786c5365355dc5886e832bbd1.jpeg

 

More "soon".

Edited by JsnPpp
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1973 2002tii (2764167), Baikal, Rebuild blog here!

In the past: Verona H&B 1973 2002tii (2762913); Malaga 1975 2002; White 1975 2002

--> Blog: Repro tii cold start relay;   + --> Need an Alpina A4 tuning guide? PM me!

 

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Lots done over the last few days. Mostly hidden work, cleaning the inside of fenders, seams and prepping for epoxy primer on the nose, inner fenders and front floor pan both sides.

 

Thankfully they are in good condition, with metal work completed on the front lower nose (by the chin) and then in the passenger foot well on the left side. I am sure I left leaves and dirt sit in the nose for too long (10+ years) and the footwell was just wet over time, people sitting with wet shoes or who knows.

 

I plan to epoxy prime the transmission tunnel and the front part of the floor pans on both sides. I'll then use brushable seam sealer and a light coat of base color.

 

I spent 4+ hours on it today and doing the math I don't believe I'll make the April 29th Mid America show. To get it done would mean I need to prep and paint:

  • Inner fenders
  • Inner doors (inside the door itself)
  • Front floor pans inside + out
  • Transmission tunnel (only the front part, in front of shifter)
  • Outer doors on the inside (the perimeter that you see)
  • Door jambs

And then

  • Engine reseal
  • Rebuild the front suspension
  • Install engine on suspension and put in car

I'd only then move to full exterior repaint; body prep, epoxy prime, primer surfacer, sand, etc. etc. and then top coat.

 

IF I can get the bullet list done by Dec 31 I would have 3 months finish the rest, which would give me a month to shake out the car, get it inspected, before the drive to Eureka Springs.

 

Think it's possible?

 

~~~

 

General shots of the interior that I am sanding with 80 grit (bare metal) and 150 grit (existing primer) to prep for new epoxy primer.

IMG_0662.thumb.jpeg.1b184ed56fbcf2465691512a7b3eafa5.jpeg

 

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A shot of the transmission tunnel, where it is today.  The brake line is twisted odd. I am going to epoxy everything up to the transmission mounts (or so) and then use the spray rock guard OR the brushable to protect. It seams that the factory did this too.

IMG_0661.thumb.jpeg.0ddc064201dd6d340ae476096e59c588.jpeg

 

For those of you preparing the front apron here is what I am doing. Mine had the teltale dents that practically everyone has (and I'm sure will come back). After general bending and a bit of hammer/dolly work, I used a vice grip to finish it off.

 

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Not bad, I did use a ruler to figure out the more obvious waves.

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I'll be prepping the front apron with rock/chip guard. The thick stuff that goes on the bottom around the entire car. Here is the passenger side today. It's actually in great condition, BUT I don't know how I can prep it for paint without damaging it. Also, the bottom of it (not really easily seen in this photo) does have some thin areas. Most likely I'll remove it (ugh, hate removing original anything) and replace.

IMG_0647.thumb.jpeg.0bfa2cb044d5ab68f63673575de61912.jpeg

 

I have Wurth brusable seam sealer that is absolutely fantastic. Wurth products also come in sprayable, but only black is available today and I like gray, even though it will be covered.

IMG_0640.thumb.jpeg.6cd7521578b62b8e86b9d04f97045f19.jpeg

 

Using a brush gives a decent texture, but does have too high of peaks. I've read that using a bit of thinner before it completely dries smooths it out nicely. I'll test before I go that route.

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The pure brush is perfect, this is dried, the brush marks are spot on. I'll do this over all seams in side.

IMG_0644.thumb.jpeg.7273b9ff9e9306ec00ae0ae3c4d7de89.jpeg

 

I actually bought 6 cans of the spray can version of the rock guard but it doesn't leave the thick tecture I want. It's a nice texture but the nose and rockers need thicker IMO.

IMG_0641.thumb.jpeg.7801cd080795ec347d167871539c215b.jpeg

 

~~~~

 

So, to keep on this at a good clip I will need to finish ALL the underbody, nose, floor pan + fenders by Sunday night Nov 26th (next Sunday). Yikes!

 

 

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1973 2002tii (2764167), Baikal, Rebuild blog here!

In the past: Verona H&B 1973 2002tii (2762913); Malaga 1975 2002; White 1975 2002

--> Blog: Repro tii cold start relay;   + --> Need an Alpina A4 tuning guide? PM me!

 

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16 hours ago, D.martijn said:

I see you straightened the upper hinge plate of the door. I've read on a German forum the factory bend the plates on purpose to make the door fit nicely with the rest of the car body. 

Great progress though!

 

Thanks!

 

Interesting Re: bend. I'll see how it all lines up once it's back, if I have to bend it back (it was slight) I'll do it.

1973 2002tii (2764167), Baikal, Rebuild blog here!

In the past: Verona H&B 1973 2002tii (2762913); Malaga 1975 2002; White 1975 2002

--> Blog: Repro tii cold start relay;   + --> Need an Alpina A4 tuning guide? PM me!

 

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2 hours ago, JsnPpp said:

 

Thanks!

 

Interesting Re: bend. I'll see how it all lines up once it's back, if I have to bend it back (it was slight) I'll do it.

 

It's the only way to get the door more towards the outside, putting shims between the hinge and door causes it to more inwards

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This stuff applied with an undercoating spray gun gives the right kind of texture.

I don't think you can get even finish with a brush, paint roller - maybe?

 

WWW.WURTHUSA.COM

Stoneguard Grey Aqua based Stoneguard for repairing and restoring the original texture in all visible and underbody area such as wheel wells, inside of door panels, fenders, underside of trunk or hood and the underbody of vehicles, front and rear valances side skirts etc. Provides...

 

 

 

 

 

Edited by Tommy

Racing is Life - everything before and after is just waiting!

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5 hours ago, Tommy said:

This stuff applied with an undercoating spray gun gives the right kind of texture.

I don't think you can get even finish with a brush, paint roller - maybe?

 

WWW.WURTHUSA.COM

Stoneguard Grey Aqua based Stoneguard for repairing and restoring the original texture in all visible and underbody area such as wheel wells, inside of door panels, fenders, underside of trunk or hood and the underbody of vehicles, front and rear valances side skirts etc. Provides...

 

 

 

 

 

 

Yes, thats the stuff. I'm using Wurth but not this one b/c it's unavailable currently (as far as I can see).

 

Dappling the Wurth brushable and then lightly wiping the peaks give a similar texture. I also thought about rolling it with a rough foam roller.

 

I'll keep testing it to see what I find. If I'm not happy with it I'll go a different brand.

 

Jason

1973 2002tii (2764167), Baikal, Rebuild blog here!

In the past: Verona H&B 1973 2002tii (2762913); Malaga 1975 2002; White 1975 2002

--> Blog: Repro tii cold start relay;   + --> Need an Alpina A4 tuning guide? PM me!

 

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I used Dinitrol with good result. No idea about stateside availability. But the foam roller might work. It's actually interesting to see as it would be handy for a small area repairwork. Full length rockers I would definitely spray if possible.

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Spent only an hour on it tonight. Too late to start with power tools, etc. so I pivoted to to removing the tar mat on the drivers side. 

 

I really didn't want to do it. No sign of rust or damage. I finally chose to do it for consistency (both sides) and also to rule out anything happening in future. 

 

I'm a heat gun vs. dry ice kind of guy.

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Doesn't take long. So, yes there was rust. BUT, it was super light, probably where water one time leaked in. Worth it for the hour long project? Probably. At least there was something.

IMG_0680.jpeg.18430aa33e348d2c5783ecdebe4a9381.jpeg

 

Almost done, I need to get the details wiped. The drain plug is tight, I believe I'll recover it with seam sealer and leave it.

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Second project was testing the brushable seam sealer texture.

 

This time I used a brush, put a decent amount on the end and applied it by tapping it. I then let it form a dry skin on top, about 10 minutes. Then I put wax paper on it and smoothed it down. The result is just what I want. Super close to how it is applied on the rockers. 

 

Thick, and the brush leaves sharp peaks.

IMG_0672.thumb.jpeg.362d2f54db90a10a2d87745788fc6393.jpeg

 

Wax paper and pushing.

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Removed the tape. Super hard to show with photo but it's smooth.

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I don't feel this is a compromise, even though the preferred application is with the gun.

 

Edited by JsnPpp
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1973 2002tii (2764167), Baikal, Rebuild blog here!

In the past: Verona H&B 1973 2002tii (2762913); Malaga 1975 2002; White 1975 2002

--> Blog: Repro tii cold start relay;   + --> Need an Alpina A4 tuning guide? PM me!

 

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  • 2 weeks later...

Where to begin? Had a four day weekend over Thanksgiving and put some serious time in when not cooking.

 

Despite the progress I didn't quite get to paint it. Ran out of time and then the weather became just cold enough to make me doubt the timing. A bummer, really wanted to get it done.

 

That being said, everything has a reason. This allowed me to pivot to a couple of other important home things.

 

What did I get done?

  • Prep both inner front fenders
  • Prep frame rails
  • Prep transmission tunnel
  • Prep drivers side and passenger side floor pans
  • Prep firewall behind heater box
  • Tape everything (now removed 😞 )

IMG_0712.thumb.jpeg.eaf0cef4b99e86109d9bdbf8b68827a6.jpeg

 

IMG_0711.thumb.jpeg.9f89f55673b92b73a1f94efc4c26d86a.jpeg

 

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One of my (multiple) disappointments is when I pulled up tape that I had left sitting for 2 months. Not a surprise but it lifted in a couple of areas. Man, how could I have been so stupid to leave the tape on it.

 

I've prepped it already, shouldn't be too hard to make it go away but we shall see.

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Next step?

 

Retape and paint. Then on to the engine! 

 

I may in the interim start rebuilding the front suspension...

 

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1973 2002tii (2764167), Baikal, Rebuild blog here!

In the past: Verona H&B 1973 2002tii (2762913); Malaga 1975 2002; White 1975 2002

--> Blog: Repro tii cold start relay;   + --> Need an Alpina A4 tuning guide? PM me!

 

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  • 2 weeks later...

Engine bay, floor pans and door jams painted! Thought it would be about 6 hours wound up to be 12 but ah well!

 

Photos tomorrow. So glad this is done - on to the engine!

 

Jason

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1973 2002tii (2764167), Baikal, Rebuild blog here!

In the past: Verona H&B 1973 2002tii (2762913); Malaga 1975 2002; White 1975 2002

--> Blog: Repro tii cold start relay;   + --> Need an Alpina A4 tuning guide? PM me!

 

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On 12/10/2023 at 5:33 AM, JsnPpp said:

Engine bay, floor pans and door jams painted! Thought it would be about 6 hours wound up to be 12 but ah well!

Well that falls in the category of successful estimate in my book 👍

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Racing is Life - everything before and after is just waiting!

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Some photos of where it stands today. TL;DR:

 

IMG_0787.thumb.jpg.80ae427e9332eac889a4c09ac906d948.jpg

 

All in all I am happy with it, despite it taking a good chunk of Friday evening + literally all day (730am-9pm) to do it Sat. Flaws? Yes, not happy with a run on the frame rail, and my two touch up spots may need to be redone. Also wish I had put down a much lighter base coat on the pan inside (really should be more like a dusting). But it will be covered with sound proofing and carpet and at least I know it's clean, dry and rust free.

 

My goal remains for this project (and I had to remind myself this) was preservation first (clean, no rust) and look nice second. It'll look great. I'm trying to get all my errors out of the way before I do the exterior.

 

I actually started looking through parts boxes and pulled the front suspension out to start working on it. Feels good to not think about body work for a bit.

 

Some photos pre-painting. I layed down a couple of coats of epoxy primer after cleaning extensively. I then covered the bare metal spots with brushable sealer. Didn't take a photo of all steps, wish I had.

 

Passenger side inner frnt fender:

IMG_0770.thumb.jpg.0b69e2f8ef0566b2da0d6a5eb974e722.jpg

 

Drivers side

IMG_0777.thumb.jpg.f684052a50ebd95d1bfcffd77c88f468.jpg

 

Drivers front floor

IMG_0774.thumb.jpg.2fade067b3f0d9dd339a6bde69a24676.jpg

 

Taping takes what feels like days.

IMG_0775.thumb.jpg.7945ae97f88a948de252bc8d0e1f850e.jpg

 

IMG_0775.thumb.jpg.7945ae97f88a948de252bc8d0e1f850e.jpg

 

IMG_0773.thumb.jpg.3f7790f63d281f15242b7bafb71aed24.jpg

 

 

And then some photos of after paint. I only cleared the frame rails, the door jams and my touch up spot. The rest is just base coat (inside fenders and on floor pan).

 

The color changes dramatically with lighting. Some of these are in sun, some are under LEDs. The car isn't purple, but yet it isn't the gray that shows up either. Baikal (at least my version of it) is really interesting.

 

In sunlight:

IMG_0786.thumb.jpg.d455b42e68006ef7038503a8afaf4c6e.jpg

 

A bit of a mix lighting.

IMG_0787.thumb.jpg.80ae427e9332eac889a4c09ac906d948.jpg

 

The pan isn't dented, its shadows from the tree outside with leaves.

IMG_0793.thumb.jpg.c1c75c98ef0fe4a63352cb93c96d7f0f.jpg

 

Mostly LED but some sun indirectly:

IMG_0794.thumb.jpg.ee8c4648f709b1596309bf149bf98420.jpg

 

IMG_0796.thumb.jpg.6a05578a7a9fca8de861b15da6555a4f.jpg

 

Way different than normal.

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IMG_0799.thumb.jpg.5450a026f2984c33190b6f03397a4386.jpg

 

 

I still need to perform some paint correction, sand a few clear sags and orange peel...

 

More coming soon! Thanks for reading.

 

Edited by JsnPpp

1973 2002tii (2764167), Baikal, Rebuild blog here!

In the past: Verona H&B 1973 2002tii (2762913); Malaga 1975 2002; White 1975 2002

--> Blog: Repro tii cold start relay;   + --> Need an Alpina A4 tuning guide? PM me!

 

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Good progress, slow and fast at same time.

 

TL;DR

  • New front wheel bearings
  • Cleaned calipers/brake lines
  • Front subframe dissambled, cleaned, repaired a torn piece of metal

  • Front subframe rebuilt w/ poly bushings, new control arms, etc.

  • New ball joints, tie rods, strut bearing

  • Some paint correction in engine bay

 

It's getting there.

 

Partially cleaned and dissambled. Nothing really put up a fight thankfully.

IMG_0834.thumb.jpg.2f5c40fab8c91f9e246783bf12a44147.jpg

 

Front suspension too. Those rotors are actually nearly new, just got wet.

IMG_0828.thumb.jpg.06c489c76e576ef007f2451a358c755e.jpg

 

A reminder of how it goes back together.

IMG_0829.thumb.jpg.4311986b29cb51b56a79851e7724b10a.jpg

 

A bit crusty but not bad. This piece of metal will need to be repaired.

IMG_0830.thumb.jpg.e19b00070408e834a082bd2e28f61b17.jpg

 

IMG_0831.thumb.jpg.7619e77833021b196961c4e191d4f984.jpg

 

Finally drained the oil after 10 years. I do hate working on the floor of the garage.

IMG_0835.thumb.jpg.a4d7771e59784914f455a9097394fd20.jpg

 

I believe this has been reinforced already. Perhaps someone could tell me.

IMG_0833.thumb.jpg.a358e38d3a251e6a890669d90583f36a.jpg

 

Removing the ball joint bolts wasn't bad. The third one that is tucked behind the others was a bit difficult but came out with a 14mm socket + a wood clamp to hold it all together.

IMG_0841.thumb.jpg.4db4a554a476e7f8c4cff1ad059d4eb5.jpg

 

Bearings starting to come out.

IMG_0843.thumb.jpeg.af65d06e7eb74f514b336eeda0fd2e0b.jpeg

 

Was delighted to have this come apart as easily as it did.

IMG_0844.thumb.jpg.7ff3e5fe62acc4b32a3a3f80a61de4da.jpg

 

Races popped out with a hammer and punch

IMG_0845.thumb.jpg.4b842a7f806eb09e44f7349d3f09c55d.jpg

 

A pause, not sure why I took this photo.

IMG_0836.thumb.jpg.e1852dbccc74acdaa08d5c6404a0d8eb.jpg

 

More on this bastard soon. A broken exhaust stud.

IMG_0838.thumb.jpeg.29fc7868101817e417e9248849b717ee.jpeg

 

Somewhat cleaned calipers.

IMG_0842.thumb.jpeg.a89c25aaaace1dcf8c460c233e792485.jpeg

 

 

More tomorrow. I'll replace the strut inserts and wrap up the hubs/brakes.

 

Ideally I'll also tackle the broken stud and some paint correction. And more!!

 

Stay tuned.

 

 

 

IMG_0839.jpeg

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1973 2002tii (2764167), Baikal, Rebuild blog here!

In the past: Verona H&B 1973 2002tii (2762913); Malaga 1975 2002; White 1975 2002

--> Blog: Repro tii cold start relay;   + --> Need an Alpina A4 tuning guide? PM me!

 

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