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Locky's Build up
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63ziggy
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Joined: June 19, 2005
Posts: 1100
Location: The Woodlands, Texas
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PostPosted: Mon Nov 22, 2010 12:14 pm    Post subject: Reply with quote

FYI

I bought a 1776 TM-10 Plus from Chico and have been running it for the past 3 months. 85hp and 105-110 tq

gotta say super nice engine

couple minor things and partially my learning curve as well (not a motor man)

Chico has been great to work with before and during.

similar, I had spoken with him almost 2 yrs before breaking down and having project ready. in that time frame, feedback did not falter and Chico was just as responsive.

even got a return call on a Sunday

enjoy that new motor
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locky
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Joined: May 08, 2008
Posts: 573
Location: Nelson, British Columbia
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PostPosted: Mon Nov 22, 2010 12:50 pm    Post subject: Reply with quote

Thanks Ziggy. I did see that you had the 1776, you must be liking it. I was just on a month holiday so I am yet still to fire it up, but should be able to get the body on in the next couple of weeks and fire that puppy up. Can't wait. I read that you had an oil leak upon fire up. Where was it and how is it now? Yes Chico has been great, a real pleasure to work with.
Keep ya'll posted
HL
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63ziggy
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PostPosted: Mon Nov 22, 2010 1:01 pm    Post subject: Reply with quote

ran into couple minor leaks. I put 2 that may be just part of the shipping or even handling during installation.

1 was at the remote filter. pulled the threaded (shaft/barb), put some new teflon and tightened her back up. no problems since.

the other is similar, leak at oil pump cover threaded (shaft/barb). same process. cured that.

dropped the oil drain cover and resealed. I was getting seepage on acorn nuts.

I do have a very very slight seepage/weeping from oil pump cover. could be gasket/seal or cover. Chico sent me a new seal and a new cover. just have not gotten on to that one.

minor stuff that were relatively quick fixes. guess it's not a VW without a leak somewhere

still very pleased with dealing with Chico and the motor
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locky
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PostPosted: Thu Nov 25, 2010 10:58 am    Post subject: Reply with quote

Ok, I have a wack of photos to post so I will start just throwing them up. Here is a shot of the chassis with the floor pans fitted not tacked and the running gear on. I had the tranny rebuilt by a local shop and mounted that as well. My old CV's still looked good except one had a bit of pitting, but not major. I blasted the axels with the bench top unit and painted the axels with por 15. New cv boots, and new brake lines, front to back. I went with the stainless braided brake lines as well. Master cylinder got cleaned up and por'd. New pedal assembly with a roller pedal.
Wheels are Steel Cragars and tires are general grabbers 205\75\15. I realize that the level of detail of the build decreases the longer I wait to post, so at this point I am just trying to catch up. Lots more to come
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locky
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PostPosted: Wed Dec 08, 2010 4:01 pm    Post subject: Reply with quote

Here are some shots of my rotten rockers coming out. I cut out the sill on the drivers side and realized I should of left it in because it was harder to line everything up. I had a moment of panick when the sill came out. The front and the back of the car were no longer attached. I did have a whole bunch of angle iron tacked all over the inside of the body to keep the alignment. I did leave the sill on the passenger side and it was a little easier, just more welding. This is my first time doing body work so getting the butt welds down were tough, I was making a mess so I opted for lap welds and filler. Turned out pretty good. Note the red floor jack in the photos. I used this to jack up the braces and then fitted the doors properly. I also built a stand out of angle iron with wheels on the bottom to rest the body on.
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Last edited by locky on Wed Dec 08, 2010 4:36 pm; edited 1 time in total
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locky
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PostPosted: Wed Dec 08, 2010 4:17 pm    Post subject: Reply with quote

Here are a some shots of the welds. Some crappy iphone photos, but shows what I did.
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locky
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PostPosted: Wed Dec 08, 2010 4:34 pm    Post subject: Reply with quote

You can see in the first photo the patch job I had to do for the front firewall section. I had to replace both sides. I got them from Basso. They were in fairly good shape but I did have to cut out some rot and patch them up.
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locky
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PostPosted: Wed Dec 08, 2010 6:21 pm    Post subject: Reply with quote

Here are some shots with the filler over the patches. First time working with filler. Pretty happy with the results. I am not totally done with the sanding yet but pretty close. I used the Evercoat fiberglass filler, I think it was short strand, but can't get to the shop right now to look. I sanded it down and then used an Evercoat lightweight filler overtop.
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locky
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PostPosted: Sat Dec 11, 2010 4:11 pm    Post subject: Reply with quote

Here is a shot of the inside rocker attached to the door post and the rear end, with glass.
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Here is the new outsid passenger rocker with the fitted and cut with the top sill off. Sorry for the crap quality of shots.
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Fitting the rocker to the used firewall piece I got from Basso.
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Chalk mark for the pan nut cutout so it would fit inside this piece
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Rockers welded in
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Trying to catch up on all the work so the detail isn't in the post and I realized I missed a bunch of shots, guess it will have to do.
Thanks for looking.
More to come
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locky
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PostPosted: Sat Dec 11, 2010 4:23 pm    Post subject: Reply with quote

More rocker shots. Notice the patch for the rear wheel well. It pretty much didn't have any metal left so I fit a piece and welded it in. Including the lower piece that mounts to the chassis
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locky
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PostPosted: Sat Dec 11, 2010 4:45 pm    Post subject: Reply with quote

Here are the two firewall pieces from Basso. They were a little rough so I cleaned them up and patched them up. Turned out great. I used the Plasma cutter to cut out all the rust and fitted the new rockers before patching them in the car. I installed one and then realized that if I make some slits in the next one I could make it smaller and then hammer that piece into what was left on my car, worked pretty good.
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locky
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PostPosted: Sat Dec 11, 2010 7:11 pm    Post subject: Reply with quote

Third time. trying this. I'm gonna.....
pics only no more patience for words Evil or Very Mad
Ok I've cooled off. Wheel wells had lots of rust and the mounts on the footrest to floorpan were completely done. So I cut them out. I used a ton of angle to keep the car somewhat aligned. I used a 2 ton jack to get the alignment correct and then hammered in 2x6's under to hold it in place. I then fitted the doors so that they opened and closed properly and left it at that.
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69vwcarl
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PostPosted: Sun Dec 12, 2010 1:40 pm    Post subject: Reply with quote

looks like alot of work keep it going man! youll be doing finish work in no time at this point it seems like theres no end but hang in there
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locky
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PostPosted: Sun Dec 12, 2010 5:37 pm    Post subject: Reply with quote

Thanks Carl. When I started and saw all the rust, I was thinking it wasn't worth it but I now have all of the rot out and yes close to the bodywork finishing!!
I had a bunch of shots that I lost due to a hard drive crash, which is a bummer, because they were the shots with the rockers completely cut out as well as both firewall sides. It looked pretty dismal. This is all I could find and they are terrible
I used a grinder with a wire wheel to get all of the old under coating off of the wheel well and then overlapped the donor piece and welded it on. I was really worried about alignment with the pans so once I had them tacked in I took the pans and fitted them to the rockers and firewall pieces. I had to drill out the dimples a little and ovalize them but seemed to work good. As you can see from the previous photos I had to use patchs on the underside of the donors and drill new holes. Once everything was aligned I went ahead and welded evertything together. On the drivers side (which I did first) I was thinking of a butt weld, but when I used the plasma I took too much off so in the wheel well on the drivers side I had to use sheet metal to overlap both pieces.
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locky
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PostPosted: Sun Dec 12, 2010 7:15 pm    Post subject: Reply with quote

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locky
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PostPosted: Mon Dec 13, 2010 3:34 pm    Post subject: Reply with quote

As I have said, when I removed most of the fender nuts, most of them broke off. So I used the plasma cutter to cut out all of the old nuts. I got some new ones from K-Mann along with new fiberglass fenders. I cut pieces of sheet metal drilled a hole in it and tacked the nut to the back side. I threaded a fender bolt in and then took the piece of sheet and slid it in the hole I made with the plasma. The sheet overlapped the hole. Then I took the fender and made sure it fit it so the nut was in the right place. I marked the correct place and then took the fender off and welded in the sheet. I did this for all of the nuts except 3 or 4. It was a time consuming job fitting and removing the fender for all of those nuts. I wanted to make sure they were placed correctley. Once I had them all in I por 15,d the welds and then used the fibreglass to fill the recession and sanded them down. I crossed my fingers and fit all the fenders back on. They all fit. Hooray!!!!
You can also see in some of these pics the patching I had to do in the wheel wells.
Heres some pics
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locky
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PostPosted: Thu Dec 16, 2010 10:27 pm    Post subject: Reply with quote

After much thought, I decided to go with the Bilstein 7100's. I searched on the samba and only found good reviews so I thought I would try them. Here is a shot of them mounted on the beam. I will post the specs tomorrow of valving etc. Easy to install and look good. You can see in the photo the grade 8 bolt welded to the top of the tower that I am going to use for limit straps. Took a page out of Michael B's book.
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And a shot of my new seats. Yonaka Ronin's. Not super high end, but comfortable and a good price. I am going to fab up some seat mounts out of square tubing and weld the seat mounts to them. Thinking of using 4 or 5 point harnesses. ANy comments are welcome.
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locky
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PostPosted: Fri Dec 17, 2010 3:27 pm    Post subject: Reply with quote

Here is the wheel combo I went with. Steel Cragars from jegs.com, General Grabbers AT2. 205\75\15. 5x4.5 (Ford) hole pattern.
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locky
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PostPosted: Fri Dec 17, 2010 3:37 pm    Post subject: Reply with quote

Fiberglass fenders I got in the summer from K-Mann. (Thunder in the background)
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Test fit while doing the fender nuts
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locky
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PostPosted: Fri Dec 17, 2010 3:46 pm    Post subject: Reply with quote

The engine bay had a hole cut in it from the previous owner. You can see it in the photo, it use to be wide open, and then I just screwed a piece of sheet metal over it. It looked sloppy so I cleaned it up and welded on a bigger piece of sheet and then used a little filler to go over the seams. Sanded it and you could hardly tell. It doesn't have the stock ribs, but what do you do. I also had a bit of a mess from replacing fender nuts on the rear passenger side so I sanded them up, cleaned the bay and then por 15'd the whole bay. I then used a rubberized undercoating to do the entire bay. Here are a couple of pics. Flash shots don't do it justice.
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