One thing I realized as we got going on this project is the problem of putting back together something that's been apart for a long time. This car (and any car, really) is a big damn jigsaw puzzle and the longer it sits apart the fuzzier the memories get. Also the shop manual can help some but it doesn't answer questions like what bolt goes where, how does this harness route, etc.

Past Jason was very smart in putting everything in LABELLED BAGS - this makes ALL the difference. We put things back together with probably 95% of parts findable, identifiable, and present. I've seen SO many projects where all the bolts and parts get tossed in a bucket. That's where 90% of the "buy my car, engine out of it" deals come from, and a very high percentage of those cars end up going to the junkyard. Project management is key.

But, even with that it really helped speed things up since I know how the engine all goes together . I was very glad to save an FD and get it back on the road. Jason texted me a picture of the new license plate for the car which really made my day - that car hasn't had a plate in 20 YEARS.

This is also something that ALL OF US can do - meet up the other guys in your community, help each other out, make things happen.

Dale

 

This x 1,000. I use old tupperware containers the wife is done with along with zip baggies to store and separate hardware for 'in process' projects.

 

Awesome build and that motor looks fantastic! Enjoyed going through this thread, brings back good memories of my ol'man showing me the ropes with flat engines back in the 80s. Those boys will be begging you to drive that FD once driving age comes lol.

 

Following me you can learn all the things not to do!

 

Thanks level7, it’s my feeble attempt at brainwashing the boys. I figured it worked on all of us can’t hurt to give it a try. As far as driving it goes, I’m all for it. I can’t let estevan62274 be the only guy doing it. And it is our duty to teach them how to drive a stick so might as well be the 7. It’s the only manual I own

Thanks again
Jason

 

While working the bugs out I noticed a small water leak. I thought it was the gasket for the thermal wax housing so threw some sealant on it.

It ended up being the oring on the thermal wax. Ray doesn’t carry the oring but does carry the thermal wax with oring for 83 bucks.

I went the cheap route and hit up auto zone.

Cleaned it up and back in business.

 

Part 2 The Highs and Lows.
After sitting in the Camp Pendleton outside storage area for about 17 years the paint needed some love. I bought a plasti dip kit for a quick coverup but the car had some dents and dings I wanted to fix so in my usual fashion changed direction and decided to paint it.
Here’s where I’m at now.

It started innocently enough. I thought I’ll just hit the dents and dings.

But then these gaps have always drove me nuts.

And it also has some weirdness where it meets up with the front fenders.

While coming up with a plan to fix all that, I ran my hand across the front bumper and realized just how wavy it was.

 

So then with new found motivation I got busy.

Filling in the weirdness where it meets the fender.


Here it is after what seemed like 4 pounds of epoxy.

Then, I gave it some poly flex filler to smooth it out some more. I put it on a little thick but it sanded down nice.

Removed all the headlight and hood trim pieces so I could go to town on the bumper. Trying to get these to the correct shape is a pain.

 

I like where this is heading!!! It's all in the prep work.
Gonna turn out awesome!

Just make sure she's done before DGRR 2024

Steve

 

Couple more rounds of sanding and she will be ready for primer.

Removing the rear bumper is full of surprises. And I thought I saw the last of this.

Wife says that Scrubbing Bubbles can be used for other things than just cars and dirt bikes. Who knew?

I think she got this puncture and some other damage on the ship coming from Hawaii.

Dented quarter panel a cracked taillight and a surprise spot of filler.

Not sure what was going on here.

Sanded down and epoxied.

Couple more rounds of sanding and I'll prime it with the front bumper.

And the wife said the project Audi had no purpose. That will show her.

 

I'm trying. It might be a primer queen but at least it starts now. We will see.
I have to admit Dale was right, going to DGRR does motivate you.

Jason

 

My Montego front bumper was the same way, that's the main reason I switched to an aftermarket bumper. I had heard the darker colors were affected like that more than the lighter colors.

I also get little spider cracks on the rear bumper, on the corner under the outer edge of the taillight where the bumper starts to curve outward. It doesn't look like you have that problem though.

 

Truthfully, I wanted to go with an aftermarket bumper as well, but with all the cash that I'm going to drop on the "paint job" I thought it would look better if I attempted to fix it myself. I'm in to the front bumper for $120, so it's not so bad. As far as spiderweb cracks go, I had those as well.



Jason

 

speedjunkie, I didn't know those cracks were a common occurrence. I figured it happened when the rear quarter was dented and taillight cracked. At least nowI won't be surprised when I see them on the other side. Thanks.

Jason

 

Did you have the cracks in this location? It kinda looks like you fixed it in the second pic. But on the previous bumper it looked more like a point with spider cracks coming from it rather than just a line like this. I always wondered what was doing it because I didn't see anything on the back side that would be poking it. I assumed it was because I have the diffuser connected to the bumper and it was pulling down on it. I'm not sure.

 

Yep, that's the same location as your bumper. The second pic is same bumper after I sanded it for a bit. I ended sanding it all down and put a layer of epoxy on it. Mine looked "to me" like the result of an impact but total guess on my part.

Your issue is obviously different. Do you have the cracks on both sides? I read somewhere that the front sags over time not sure if the rear does as well. For the front bumper, I put a couple of layers of epoxy on the inside to strengthen it a bit. Not sure if it will amount to much but had to do something.

Jason

 

Can a moderator disable this spam account?

 

Yeah I have that crack on both sides. And on the old bumper too. I've had the diffuser on for years so I don't remember if those cracks were there before that, and I haven't looked at other FDs to compare.