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My *early 71* Project-No.2


jerry

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it has been WAY too long since i've posted anything to this project. i've been sidetracked for the past couple years on other 02's. it's time to get this one running.

what i've done during the past couple years:

rebuilt steering box, front suspension

the suspension sat idle for over 3 years until i installed it last december 2010

i swapped in a Schrick 292 camshaft last week

i added a 5 speed transmission

i installed the engine/tranny last week

i'm debating whether to swap out the standard brake booster for one of my tii brake boosters in case i go through with a sidedraft carb setup.

i fabbed all my 5 speed conversion bits, including the rear brackets, shortened shifter platform, shift rod and shortened support bars.

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Former owner of 2570440 & 2760440
Current owner of 6 non-op 02's

& 1 special alfa

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Do you have any comparisons between the Ford Wimbledon White and Chamonix? Is the Ford color brighter?

i am very happy with the choice of Wimbledon white. it is almost a dead-ringer for the chamonix on the car. it has a VERY subtle ivory softness to it that is absent in some of the harsher whites like alpine white used in later bmw's. i do not like bright white on roundies.

Former owner of 2570440 & 2760440
Current owner of 6 non-op 02's

& 1 special alfa

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  • 2 months later...

i've dabbled on and off on this car for the past couple months. I swapped out the standard brake booster for a tii booster i had on hand. this included bending new brake lines up front as the tii booster puts the master cylinder forward about 2 1/2 inches.

stripping out the interior floor tar lead to a very pleasant surprise. this particular car has what is probably the cleanest floorpan i've ever seen to date. local surface rust is all i had to deal with. no metal perforation. absolutely none!!!!

this is a welcome change from the rust i'm dealing with on 2760440.

I also spent the last week nights rebuilding a batch of 4 heater boxes, so i wont be needing to do that task for awhile.

next step is to install the heater box, swap out the top 2 pieces of the dash for a crack-free setup i have and install a new carpet.

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Former owner of 2570440 & 2760440
Current owner of 6 non-op 02's

& 1 special alfa

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  • 2 weeks later...

well, i got alittle ahead of myself on this project thinking i could install the carpet and battery cable to the trunk. it had been awhile since i really looked in the trunk and it was clear to me that the trunk needs a thorough going through before i even think of the interior. if i can get some decent warm weather before winter i'd like to shoot the trunk to make it all shiny new looking.

first up is patching the spare tire well. although i have a couple spare tire wells lying around i always prefer to keep as much of a car as possible. it's a lot of work piecing the bits together but i think the extra work is worth it.

after the tire well is sorted i'm off to fixing a couple rust spots near the trunk hood latch and by the rear fender well. i also determined that the tail piece and passenger side quarter panel were replaced at some time. that explains why this car looks cleaner on the passenger side as compared to the driver's side.

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Former owner of 2570440 & 2760440
Current owner of 6 non-op 02's

& 1 special alfa

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i'm working my way around the backside of this car. it's time consuming. small patches can be just as much work as larger patches. i am lucky enough to have a spare used rear quarterpanel that has just the pieces i need to deal with the remaining rust spots. it's very satisfying to slowly see a car loose small rust holes that have probably persisted for decades. my goal is to get the trunk painted before the weather turns wet and cold.

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Former owner of 2570440 & 2760440
Current owner of 6 non-op 02's

& 1 special alfa

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  • 3 weeks later...

i'm in a mad dash to get 2-stage paint in the trunk and around the rear window before the weather gets much cooler and the days much shorter. i spent an afternoon scrubbing the rear underside of the car clean of a waxy rust preventative. it certainly kept this car in reasonable shape. i gave the rear wheelwells and underside a fresh coating of rubber undercoating followed by an application of DuPont epoxy sealer. i sanded as best i could the area between the rear window and trunk opening where surface rust had taken hold. wiped the whole area with wax and grease remover followed by a coating of etching primer from a spray can. after that, everthing was coated with the DuPont epoxy sealer. i hope to spray a light coating of sandable 2K primer then sand up to 400grit followed by color. the primer will only be sprayed to the exterior sections and not the innards of the trunk or underneath.

overall, i'm very pleased at how the sparetire well came out. no apologies and it gives me hope on my next project.

my goal is to get the trunk and rear windshield area painted so i can close up the car for winter. then i can reinstall the rear suspension and get the car running. bodywork will be done if phases next spring/summer.

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Former owner of 2570440 & 2760440
Current owner of 6 non-op 02's

& 1 special alfa

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  • 1 month later...

next up is the driver's side door. it has common rust at both bottom edges and along the bottom edge. i am loathe to swap out original body parts if i can save the original bits. this car has its original doors including the adhesive VIN sticker.

i must admit that it is a considerable amount of work to do the job correctly but i find rust repair very rewarding. every little patch brings the car one step closer to prepping for paint.

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Former owner of 2570440 & 2760440
Current owner of 6 non-op 02's

& 1 special alfa

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great work. must be nice to be able to do all this yourself

thanks for the complement. it really comes down to a willingness to make mistakes and learn from them and try to learn from the work of others posted on this board.

practice definitely makes perfect as the work on this car is definitely better than my first project i posted in this section. i look at those earlier welds and am grateful that i'm capable of improvement....

i started by buying a used Craftsman Mig welder on Craigslist which i later sold after buying a Lincoln welder also on Craigslist. My paint guns were all bought used on eBay. my sheetmetal stock is old shelves that were tossed out at work. i think the other area of improvement is actually shaping the metal using hammers, an anvil and creative use of clamps, supports and bending.

Former owner of 2570440 & 2760440
Current owner of 6 non-op 02's

& 1 special alfa

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  • 3 weeks later...

i thought i'd do a little update. i've finally completed all the rust repair on the DS door. i'll wait to do final paint and bodywork on it for later. at this point it's primed and protected from further rust advance. before i reinstall it i will fix the rust found on the rear rocker panel shown in an earlier post.

i took an exploratory cut in the panel and am pleased that most of the damage is limited to the lower portion of the rear quarter panel. i'll be able to cut a replacement from one of my spare panels i have on hand. this repair should be alot easier than the door repair.

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Former owner of 2570440 & 2760440
Current owner of 6 non-op 02's

& 1 special alfa

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  • 2 weeks later...

here's a couple photos of the lower rocker panel repair completed. i decided to cut out the inner portion of the panel shown above since i inadvertantly cut it anyway. i was very pleasantly surprised to see how clean this car is as can be seen in the photo.

it's very satisfying to slowly check-off the items on the imaginary 'to-do' list in my head.

next up is reinstalling the DS door with the internals all cleaned, lubed and ready to go. then i'm off to the PS door for some minor rust repair and R&R of the internals.

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Former owner of 2570440 & 2760440
Current owner of 6 non-op 02's

& 1 special alfa

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