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  #21  
Old 07-03-2020, 09:39 PM
cmartin cmartin is offline
 
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Cool project, keep it coming.
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  #22  
Old 07-06-2020, 09:58 AM
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Looks like a fun car!
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  #23  
Old 07-06-2020, 06:18 PM
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Well, I didn't make as much progress as hoped this weekend.

I went to reinstall the window wiper mechanism, and ended up breaking the 47-year-old rubber isolator mount. <sigh> So, time to order another part and wait for it to arrive....

In the meantime, I fixed the control cables for the heating & ventilation system. Don't know why, but some of the cables were connected to the wrong locations.

And, I fixed the stripped nut in the decklid mount. Since (I hope) everyone likes pictures, I took a bunch of this process. Of course, it took as long to take all the pics as it did to perform the actual repair.

First step is to drill out the bad threads. Fortunately, the DAPO didn't over-drill the hole, it was just about the right size.
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Then, I tapped the hole with the helicoil tap:
Name:  tapped.jpg
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Then, to make sure the helicoil won't come out, I added some red loctite.
Name:  loctite.jpg
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Next step was to install the helicoil insert. Here's a pic of the install tool, with the insert about halfway installed:
Name:  inserting.jpg
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Final step was to break off the driving tang. The full kit comes with this special "breaker" tool (aka, a piece of steel rod), but it can be done with a screwdriver if you just buy the basic kit.
Name:  breakingtang.jpg
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All done. This won't come out without destroying the mount.
Name:  done.jpg
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Size:  167.8 KB
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Last edited by BillC; 07-06-2020 at 06:33 PM.
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  #24  
Old 07-06-2020, 10:29 PM
KONG KONG is offline
 
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Quote:
Originally Posted by BillC View Post
Well, I didn't make as much progress as hoped this weekend.

I went to reinstall the window wiper mechanism, and ended up breaking the 47-year-old rubber isolator mount. <sigh> So, time to order another part and wait for it to arrive....

In the meantime, I fixed the control cables for the heating & ventilation system. Don't know why, but some of the cables were connected to the wrong locations.

And, I fixed the stripped nut in the decklid mount. Since (I hope) everyone likes pictures, I took a bunch of this process. Of course, it took as long to take all the pics as it did to perform the actual repair.

First step is to drill out the bad threads. Fortunately, the DAPO didn't over-drill the hole, it was just about the right size.
Attachment 62602

Then, I tapped the hole with the helicoil tap:
Attachment 62603

Then, to make sure the helicoil won't come out, I added some red loctite.
Attachment 62604

Next step was to install the helicoil insert. Here's a pic of the install tool, with the insert about halfway installed:
Attachment 62605

Final step was to break off the driving tang. The full kit comes with this special "breaker" tool (aka, a piece of steel rod), but it can be done with a screwdriver if you just buy the basic kit.
Attachment 62606

All done. This won't come out without destroying the mount.
Attachment 62607
You weren't kidding about the new toy. Cabin fever got you good!
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  #25  
Old 07-09-2020, 09:10 PM
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The order with the rubber isolator finally came, so I installed the wiper motor and wipers.
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Name:  wipers.jpg
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The hardest part of the installation is the nut for the other end of the isolator. It hides under the dash, and is very difficult to reach with the dash in place. Fortunately, if you take out the ashtray mount (two phillips screws and push forward to unclip), you can just barely get access with a 1/4" drive deep socket (10mm) and a universal joint. The red circle shows the inside nut.
Name:  inside-nut.jpg
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  #26  
Old 07-11-2020, 06:12 PM
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Today I worked on reinstalling the fresh air box. With a new top gasket and an intake screen (came on '74 and later 914s), it was every bit the royal pain that they said it was. But, here is the box installed:
Name:  installed.jpg
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Because it was such a pain to get the two bolts installed, I had to get creative. I got the driver-side bolt in okay, but couldn't get the box high enough to get the passenger-side bolt in. So, I decided to make a "mini jack" with a tall socket and a brake pad spreader.
Name:  mini-jack.jpg
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This got it up high enough to get the last bolt in.

Then, I connected the cable to the fan box. This was almost as big a pain as installing the box itself. No pics, since I had to do the job basically by feel.

Then, the hoses were reinstalled. First the paper hoses to the ventilation system and then the drain hoses. One of the old hoses broke, so I had to get new hoses. Unfortunately, they don't quite match the old ones.
Name:  paperhoses.jpg
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Name:  drainhoses.jpg
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  #27  
Old 07-12-2020, 04:27 PM
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Time to tackle the hacked-in hole by the foot pedals. Here's what it looked like before I started:
Name:  hole-initial.jpg
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I didn't really want to cut another hole in the car, but there was no way I was going to be able to reform the hacked metal without an access hole on top of the center column. The bit in the top of the hole is the old accelerator cable -- the liner was stuck in the tube and I needed the access hole to get the liner out through the front end of the tube. Once I'm all done with the welding and painting, I'll make a panel to cover the hole, which will be attached with butyl rubber so it can be accessed in the future.
Name:  accessHole.jpg
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Here's the hole and the patch (what was originally cut loose) after reshaping.
Name:  patch-reshaped.jpg
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And the patch fitted in place. There's a copper bar behind the patch, to act as a temporary backing plate for the welding.
Name:  patch-fitted.jpg
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Patch welded and then ground.
Name:  patch-welded.jpg
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Name:  patched-ground.jpg
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Here's what the clutch tube looked like:
Name:  clutchTube-Orig.jpg
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Even though the clutch tube still looks well-attached, I decided I might as weld in a support strap while I had easy access to it. I bent a piece of 3/16" wire into a loop about 5/8" inside diameter. Then, I drilled two holes, above and below the clutch tube, and placed the strap.
Name:  strap-inPlace.jpg
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Here's the strap welded to the tube support. Not the greatest welding job (access wasn't good, even with the access hole), but it should hold.
Name:  tube-welded.jpg
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On the outside of the center column, you can see where the strap protruded.
Name:  strap-beforePrep.jpg
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So I trimmed the ends of the strap in preparation for welding:
Name:  strap-preppedForWelding.jpg
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Here's the final result, after welding and grinding:
Name:  outside-allwelded.jpg
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Size:  185.7 KB
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2016 GT4 warp 7
1999 SPB warp 2, maybe
1973 914 2.0 1/2 impulse

Previous:
1973 914 1.7 1/4 impulse
2012 Cayman R warp 4
2006 Cayman S warp 3
1966 911 stuck in space dock
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  #28  
Old 07-13-2020, 07:43 AM
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Nice work. I will be able to use this info once I get in to my 914.

Thanks for posting.

Cheers
Engelbert
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  #29  
Old 07-13-2020, 08:17 AM
cmartin cmartin is offline
 
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Nice job with the airbox. Thats one of those jobs I shake my head at. Maybe I'm too old and fat but its usually much tougher than it looks. Reminds me of the setup in my old SL, I think benz built the car around the hvac system.

Keep at it, good progress
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  #30  
Old 07-13-2020, 08:27 AM
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MB built the E- class around the HVAC box too.
I have a 914 in the shop that someone over sprayed the screen in the cowel Not looking forward to correcting this.
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