A lot has been done since my last post, but so little time to document it here. I was able to repair most of the Factory Air conditioner parts under the dash; the vacuum hoses were replaced and reconnected, the vacuum motors inspected and cleaned and the electrical connectors replaced. The variable resistor was replaced with a new Scott Drake piece.
The wiper motor, air vent and washer pump assemblies were disassembled, cleaned, primed, re-painted and lubed. Everything was tested and only 1 motor failed; the air vent actuator motor at the heater box. This one will be easily replaced from underneath the dash later on.
Then it was all assembled
the hidden cowl surfaces were cleaned and re-coated with rattle can paint to add a measure of rust protection. Then the grounded plugholes were coated with Weld-Through 2 spray compound.
Firewall insulation was installed. We used Thermoshield heat and sound insulator from Pep Boys (4x6' for $34.0). Later when we do the interiors, we will consider using it for the rest of the floor. (update, Sept 24, 2013: I removed this stuff and bought a Mass-Back carpet that eliminates the need for any other insulation barriers CID).
(October 2013 Update: I removed this stuff and decided to install a Mass-back carpet from ACC)
Prior to clamping, we insured we left no loose hoses or disconnected wires, that we could not get from under the dash.
Then we laid down the cowl, clamped it, test-fitted the fenders, and began plug-welding. Both of my kids helped a lot with the fitting, clamping and welding.
It took us about 1 hour to plug-weld the entire cowl. Following a good piece of advise, I replaced the flux core wire from 0.035 to 0.030. It made a world of difference! We welded with confidence knowing that we were no longer welding through the sheet metal like before. And spatter was greatly reduced. Most plugs were rounded, clean and pretty with a lot less spatter.
After a little grinding, we re-plugged a couple of plugs and coated the plugs to keep them from rust-flashing. We were happy with our work. Hey! we saved over $1,000.0 doing this ourselves!
http://www.youtube.com/watch?v=0b0LpuAPDas&feature=youtu.be
The wiper motor, air vent and washer pump assemblies were disassembled, cleaned, primed, re-painted and lubed. Everything was tested and only 1 motor failed; the air vent actuator motor at the heater box. This one will be easily replaced from underneath the dash later on.
Then it was all assembled
the hidden cowl surfaces were cleaned and re-coated with rattle can paint to add a measure of rust protection. Then the grounded plugholes were coated with Weld-Through 2 spray compound.
Firewall insulation was installed. We used Thermoshield heat and sound insulator from Pep Boys (4x6' for $34.0). Later when we do the interiors, we will consider using it for the rest of the floor. (update, Sept 24, 2013: I removed this stuff and bought a Mass-Back carpet that eliminates the need for any other insulation barriers CID).
(October 2013 Update: I removed this stuff and decided to install a Mass-back carpet from ACC)
Prior to clamping, we insured we left no loose hoses or disconnected wires, that we could not get from under the dash.
Then we laid down the cowl, clamped it, test-fitted the fenders, and began plug-welding. Both of my kids helped a lot with the fitting, clamping and welding.
http://www.youtube.com/watch?v=0b0LpuAPDas&feature=youtu.be
Outstanding! Your daughter is a talented young lady. I'll bet you're a proud papa right about now. Thanks for the video.
ReplyDeleteIvan, Great video and explanation. I'm glad the .030 diameter wire works better for you. :-) Your daughter is going to have great skills when you're done with the car. Not only that, but you're building a great relationship with her that's priceless!
ReplyDeleteThank you guys and thank you Dennis for the advise on the flux core wire change. The improvement in the welds (and my morale) was huge.
ReplyDelete