Author Topic: Popbumper's '76 wagon - update (Read 80480 times)

popbumper · « **Reply #30 on:** January 14, 2009, 10:00:28 PM »

Update for January 14th, 2009

The side blessing of being laid off (that's a hard one to say

) is having the time to get some work done. As we last visted, I had pulled my gas tank off, including the filler pipe, straps, and rear bumper insert. First task at hand - get stuff sandblasted. More pics on thsi later, the parts turned out GREAR and have already been painted with POR-15.

Tonite, we visit the venerable gas tank. Yes folks, just about everything that could be wrong with a tank was wrong with this one:

1) One 3/16" hole, and many small pinholes
2) A bad sending unit
3) A lot of oversprayed undercoating (not really an issue, but it was messy)

First things first: Tank comes off, parts come out, and I carry it to a car wash to spray it out. Then, off to "Poor Boy's" Radiator shop to get some brazing. This cost me $80, and took about a week and a half. Sending unit? Scored a NOS unit for $75. Also managed to get ahold of a new vent assembly and filler tube gasket from SSC Enterprises (www.sscenterpr ises.net).

The pictures below show today's work, after I picked up the tank. The "tank top after" shows the top coated with a fresh layer of silver POR-15; all the undercoating was NOT removed because I was less concerned about this unseen area. I have yet to replace the pad, and I also plan to cover the top with fresh undercoat. I have not decided what to do with the bottom yet; now freshly stripped steel, I may either polish it out and coat it with clear POR-15, or use their "steel" color coat. In either case, I need to address the "bumps" of the brazing.

Finally, the tank will be coated internally - it really needs it (there is evidence of rust). This will be done sometime next week, and then everything will be carefully reassembled. Total cost - about $200 +/-. Not what I would have expected, but I really do NEED to know how much gas I have, and, keep it IN the tank.

More soon!

Chris

popbumper · « **Reply #31 on:** January 14, 2009, 10:03:00 PM »

I forgot to add - the bottom of the tank, as you can see, had been "pre-scraped" of undercoating so that the radiator shop could braze the hole/pinholes. After I got it back, It took me about three hours to completely scrape off the remaining undercoat with a putty knife, mineral spirits, and plenty of elbow grease. I love the clean metal look!!

Chris

hellfirejim · « **Reply #32 on:** January 28, 2009, 12:48:13 PM »

hey Chris,
Glad to see progress on your wagon. Just keep at it a little at a time and it will get down.

jim

popbumper · « **Reply #33 on:** March 21, 2009, 10:21:56 PM »

Update for March 21, 2009

Hello again all, last time we visited I was in the throes of removing my leaking gas tank and finding it was a bit more of a job than I had anticipated. Now, with the weather warmer and days longer, I am happy to report that I have made yet another jump in the process of this wagon restoration. To recap the effort:

DONE:

1) Bad brake system rebuilt (new master cylinder, hoses, hardware)
2) Rusty floors repaired
3) Dash pad restored (pics will be in another thread)
4) Gas tank restored

TO BE DONE:

5) Cowl hole repair
6) Pull windshield and replace gasket
7) Remove/restore dashboard with window out

Restore/rebuild front end

TASK #4 - The gas tank was completed today. All undercoating was removed; pinholes were patched at a radiator shop. Then, the "welds" were gently ground down, and the surrounding surface was smoothed with a small bit of bondo. I also purchased an NOS sending unit, and new valves/gaskets from SSCenterprises .net.

The tank was flushed with POR-15 materials to properly "degunk" it and etch it for sealing. Then, the tank was treated with POR-15 gas tank sealer, which did a GREAT job of lining the tank with a hard, durable surface.

To finish, any other dents in the tank were also filled, and the whole think was carefully sanded down to bright metal, at which point I used POR-15 "Metal Mask" paint to cover the surface. This is an excellent coating that dries in a natural metal shade.

My wife realized how tedious the restoration process was, and looked at me and kept telling me "hey, it's only a gas tank, nobody will ever see it". You know, I love her to death, but she just doesn't get it...

The pics here reflect the final stages in the process before reinstallation; one of the pics takes you back to where I started after the radiator shoppics. Judge the results for yourself. I also spent part of the morning wire brushing the old undercoating around the gas tank and up under the rear wheelwells in anticipation of freshening up the undercoating and reinstalling the tank. I love this stuff....one step at a time.

NOTE: There was no particular reason I turned the tank in the opposite direction for the "painted" phot, I just shot it that way. There is NO evidence of the welds whatsoever, the tank looks nearly new. The ONLY caveat I have is that the paint dried VERY fast for one reason or another (see the shading issue?) - and went on thicker than I wanted it to. POR 15 is GREAT, but this particular can/batch/formulation did not behave well.

discolives78 · « **Reply #34 on:** March 21, 2009, 10:51:40 PM »

Well, at the moment, I'm thinking a lot of people will be looking at your gas tank. Besides, if shiny is good, does that mean that only the upper surface of the car should be shiny? I have a shiny valve cover, most of the time I'm the only one that knows, but every once in a while somebody sneaks up on me when I check the oil.

Glad to see you're making progress, still waiting for the dash pics!

Chuck

popbumper · « **Reply #35 on:** April 05, 2009, 07:32:47 PM »

Update for April 05, 2009

Well, no pics to share today, but my gas tank is officially reinstalled. Spent the day yesterday "freshening" up the undercoating beneath the rear end of the car, and got the tank installed.I actually put a thin (1/16") layer of adhesive sheet cork on the gas tank straps so the straps would no longer contact the gas tank (yeah, I went overboard, sue me :cheesy_p:). Everything looks great, it all snugged up nicely. Cut a new cork gasket for the filler neck, installed all new rubber hoses/clamps at the sending unit and vent valve, poured a few gallons of gas in, and took her for a ride!!

She still drives fine, though the steering DOES "knock" when I turn the wheel.

I >love< making progress!! NEXT ON TAP: Front end rebuild. Might as well get it out of the way, it's definitely time. Gonna spend the $$ while I have them.

Chris

popbumper · « **Reply #36 on:** April 07, 2009, 09:42:47 PM »

Just a quick note - never having rebuilt a front end (well, except on a '57 Chevy), I have been "studying" my shop manuals and my parts CD. You know, it really helped - I took a look up under my front end tonite, it all makes sense, and looks pretty straightforwar d. Everything really needs done, and it's going to look awesome when all the parts are fresh and clean. I will order parts tomorrow.

As a side note - while I was up under the car, I took a metal scraper and started pulling some of the road grime/mud/dirt off the front crossmember. I was "awarded" with original body paint that is still intact. The oil pan also looked near new when wiped off with mineral spirits. Gotta love dry climate cars - you'd never see anything but rust on a Northern car (ducking now.....) :evil:

Chris

78txpony · « **Reply #37 on:** April 13, 2009, 09:34:28 AM »

Chris,
Here is the parts list I found from when i redid my front end 5 years ago. The list is not too detailed, but I was not as organized then.
This was a very straightforwar d operation from my experience. No spring compressor was needed; I can walk you through how I did mine. I did one side at a time. Car was supported under the front crossmember. Floor jack was used to let lower arm down when removing spring, steel rod was run through shock area as a safety precaution. Never had an issue though. Control arm bolts are left loose until entire job is done and full weight of the car is on the suspension. Everything is torqued then.
Let me know if you need some help or extra tools.

Rack and pinion gear (manual)
tie rod ends (2)
Upper ball joints (2)
Lower ball joints (2)
Upper control arm bushings
Lower control arm bushings
Strut rod bushing set (2 sets)
Wheel bearing set (2 sets)
Wheel bearing seals (2 sets)
Front brake hoses (2)
Brake pads (if needed)
Shocks (2) (if needed)
Sway bar bushings
Control arm bolts - see http://classicoldsmobile.com/forums/chassis-body-frame/12099-arm-bolt-breaks-front-wheel-falls-off.html for the reason these should be replaced...
Shop labor to R&R all bushings

Wheel bearing grease
Grease gun for new ball joints

Get Moog parts when possible, aviod the cheapie parts. This is a job you go not want to do over...
My whole cost was about $1000, but Rockauto is a better place to get parts like these... I could have saved at least a few hundred.
But was it all worth it?? Heck yea!! :lol:

popbumper · « **Reply #38 on:** April 13, 2009, 10:26:27 AM »

Hey Rob:

Good to hear from you - my bad for not posting our car meet. GOOD NEWS - the front end is stripped out, I did it (with the help of another car guy I know) this past Saturday. It took six hours, and the lower control arms will not come off. He is bringing over a sawzall today to cut them loose.

Been studying all the parts, gonna start parts ordering today. Most of the fromt end parts (sway bar, control arms, strut rods) will be sandblasted and painted with POR-15 prior to reinstallation . Remember that wonderful "hole" under my battery tray? It's MASSIVE, I am going to have to fabricate a sheet metal piece to fill the area and repair it. It's a big mess, but now is the time to get it done.

Stay tuned, thanks for the list!

78txpony · « **Reply #39 on:** April 13, 2009, 11:00:03 AM »

Let me know if you need an impact wrench. I needed one to loosen the control arm bolts and the steering gear bolts. Make sure you replace all those load-bearing bolts with correct types and grades. I almost lost a wheel on Saturday due to a bolt stress failure. I will be free after work most of this week so if i can help, let me know...

popbumper · « **Reply #40 on:** April 18, 2009, 08:42:18 PM »

Update for 4/18/09

Been a busy Spring. Taking advantage of our wonderful, cool weather, trying to get some major work accomplished. Thanks to the help of a good friend (Gene Quinones), much progress has been made on the front end - whose suspension and btrake system has been completely dismantled. At this point, all the parts are either slated for sandblasting and refinishing, or are being replaced. Once all is said and done, I will have:

New bushings throughout, tie rod ends, shocks, springs, calipers, rotors, shoes
Refurbished control arms, strut rods, sway bar and hardware, wheels (more in another thread)

Picture 1 shoes the results after we had gotten to the lower control arms, which would NOT come off. The bolt has seized to the bushing lining, and we had to sawzall the bolt at either side - on BOTH arms. What a pain.

Picture 2 shows the box 'o goodies that came off he car. All this will be fresh and new in a few weeks.

Picture 3 shows the horrific rust I have on my passenger inner fender well. Looks liek to only good solution is to find a donor car (already located), saw out a fender, and weld in a new one. As much as I hate to do it, it HAS to be done right.

...making PROGRESS....

Chris

popbumper · « **Reply #41 on:** April 21, 2009, 01:16:39 PM »

Update for 4/21/09

Picked up the new rotors, shocks, springs, calipers, shoes on Monday. Dropped off a bunch of stuff at the sandblaster an hour ago. $200 and my front end pieces and rally wheels will be nice and clean.

I could have had the wheels powdercoated for $300 total, but one of the wheels has corrosion on it, and the pitting would show through the coating. Bummer - paint is the only option, I'll have to get a good durable epoxy paint or something such.

Still need to buy all my front end bushings, ball joints and bolts. Gonna be a banner month for spending money - but like I said, it's progress.

Chris

billnall · « **Reply #42 on:** April 21, 2009, 06:37:45 PM »

Chris your inner fender apron that has all the rust holes, I located an NOS one at Green Sales (800-543-4959) if you want to go that way part# D5FZ16054A. I also found a battery tray NOS @ a Ford Dealer, I can pm the info if you want it.

popbumper · « **Reply #43 on:** April 21, 2009, 06:56:34 PM »

Bill:

Getting a replacement battery tray sandblasted today. On the inner fender - I imagine that it would be expensive to ship - and, unfortunately it would need welding (for that matter, a used one would, too :nocool:).

Thanks for the heads up!

Chris

popbumper · « **Reply #44 on:** April 24, 2009, 09:50:28 PM »

Update for April 24th

...so my wife calls me today at work. "You got a letter from the City about your Pinto". "Oh?" "Well, according to City regulations, any car exposed to public view in a driveway or otherwise needs to be titled and operating". OK....

...I phone the person who wrote it. She was actually nice. To my dismay, I had removed the rear bumper recently, and, of course it has the license plate on it. Before I tore off the front end, I turned the car around, back of car facing outward - and it was, sadly noticed for the wrong reasons.

I explained to the woman that the car did run, was registered in my name, had plates, and is properly titled but not yet inspected. "Can I come by to see it?" "I just need to have you start it up and move it back and forth". "Um...sure (gulp...knowing my front end suspension is completely off the car). ..."Sure, when"? "How about Saturday May 9th?" (I have 30 days from notification).

The rest of the day was busy. I picked up my parts from the sandblaster (whew, glad they got done). Monday morning I order my front end kit, bushings and all, and make a quick but important Rock Auto order. The next few days are heavy with painting parts and getting things in order. Next weekend, it all goes back together.

I told my wife I was proud of my little car...after all, someone from the City wants to come and see it run :lol:. She was not amused.

Chris

...still making progress, UNDER PRESSURE..... :mad:

75bobcatv6 · « **Reply #45 on:** April 25, 2009, 01:13:15 AM »

lol I am amused. that was funny yet sad. Im sorry to hear that man. They have not said crap about my car, its titled, but not Registered No plate, and backed into a space. =) No one complains cause they see me working on it every chance i get.

dga57 · « **Reply #46 on:** April 25, 2009, 02:13:00 AM »

Nothing like a little "official" inspiration, eh? :rolleye: Who knows? Maybe when the lady from the city comes out to look at your car she will fall in love with it and you'll make a new Pinto friend.

Godspeed on your project!

Dwayne :smile:

78squirewagon · « **Reply #47 on:** April 25, 2009, 07:54:26 AM »

I got a letter just like (about 50 days ago) that from the City of West Allis WI concerning my white squire wagon

Yeah, it lite a fire under my butt to get plates for it and to start working on it again. They were pretty cool about and do not have to come and take a look but when are are threating to tow it away, it will wake you up

TIGGER · « **Reply #48 on:** April 25, 2009, 02:31:31 PM »

I am glad Oregon is not like this.

78txpony · « **Reply #49 on:** April 26, 2009, 07:41:45 PM »

The nice thing is that Pinto front ends are not too difficult to put back together. The hardest and most time consuming is disassembly, cleaning, and painting.
Let me know if you need some assistance, guidance, motivaction, or comic relief!

Also let me know if there was anything you still needed off that carcass we left in the yard - I ~might~ go back later for that back bumper, since mine is cracked so badly... I would need hip waders after all the rain they are predicting, but maybe that would help postpone its upcoming destruction.

popbumper · « **Reply #50 on:** May 05, 2009, 09:40:07 PM »

...Hi, I'm Chris, and I'm a Pintoholic.... :drunk:

I'm tired. I have no updates right now. I'm tired. I have been busting my a$$ trying to get everything ready for my front end reassembly this weekend. Did I mention I'm tired....

..and probably a little loopy. :drunk: Sniffing paint fumes for hours on end tends to get you after a while.

...and yes, I just got out of the garage. I was out painting with POR-15. "Painting what" you say? Oh...um...my ball joints, before I attach them to the control arms.

No, I knew better than to paint the greased knuckle, and I was careful not to get paint where it should not be. This dam% car might as well be a show car, cripes, EVERYTHING on my suspension is restored, sandblasted and painted, or fresh out of the box. All the metal screws and nuts are stainless..... .

It's a disease, I tell you. Did I mention I'm tired? :drunk:

Chris

PS - pics this weekend. After that, I rest. And then I restore the friggin dash that I pulled from the 78 hatch last weekend. Oh, and then the windshield comes out, and then the rear end comes off, and then I replace the inner fender panel, and then.....>thud<

......zzzzzzzz zzzzzzzzz..... ...

popbumper · « **Reply #51 on:** May 11, 2009, 09:45:44 PM »

Update for May 11th, 2009

When we last visited, I was "complaining" about how tired I was working on my car :drunk:. Well my friends, now that the work has passed, I am on to greener pastures. Well, at least a short "break" before I go to the next level

. A few posts back, you saw my nasty, nasty box of cruddy, rusty, and unloved original front end parts. :reek: This past weekend, the front end got rebuilt. Yeah, I'm partial -it's DA BOMB!!

I have to thank both 78TXPony (Rob) and my Comet friend Gene for taking the time to help. Six hours were spent Saturday reassembling all of the new parts, and I have to say, I was actually >sad< to put new parts on my "unfinished" frame, but without shop space and a rotisserie, it's "one step at a time" getting this stuff done. Here's some pics of the process.

"Ugh before" is a revisit of what it used to look like
"Restored parts" shows all the stuff neatly laid out and waiting for reinstallation
"Mocked lower" shows a prefit of the parts, just to get an initial visual
"Prepper rotor" shows the restored spindle/rotor/caliper assemblies

beegle55 · « **Reply #52 on:** May 11, 2009, 09:49:24 PM »

B-E-A-U-T-I-F-U-L. Great attention to detail and that hard work has to be paying off! It will ride so smooth and drive great... while looking good too!

At least there is more than one crazy person on this site, we all fit in together very nicely.

-beegle55

popbumper · « **Reply #53 on:** May 11, 2009, 09:55:43 PM »

What I did not show is the "cleanup" process; since the inner fenders need some work, and I want to remove the fenders before I really undercoat them properly, what I did is pay attention to ONLY those areas I knew I could not get at after front end parts were reinstalled.

I cleaned the towers with Mineral sprits, as well as the frame areas. Then, the towers were repainted with two coats of POR-15; metal, then "Chassis black". This gives the areas the toughness they need. The parts them selves had three coats of paint - one of metal POR-15, one of chassis black, then one of body paint - "Charcoal grey metallic". Red accents were a must, so I painted the calipers and ball joints. All hardware is stainless steel, and the front end kit is P-S-T. The frame areas were recoated with fresh undercoat.

Rotors, brake pads, calipers, and springs from Autozone
Small hardware, bellows, etc. from Rock Auto

I am very happy with the results, the new parts look stunning and will be beautiful when I put my rally wheels back on. My biggest issues now?
1) get everything else to look as nice
2) get the front end realigned - it is very obvious that the wheels are "crooked" in the driveway.

It was several weeks of work, but well worth it. I cannot believe how the front end sits up at the CORRECT HEIGHT now!

Final result photos - show the driver's side nearly complete. Brake hoses still need to be hung, as well as the sway bar.

popbumper · « **Reply #54 on:** May 12, 2009, 08:31:56 AM »

So I gotta ask - in this project forum, is it even worth the time to post anything? There's a lot of work involved in taking pics, resizing them, moving them around, and then posting. It seems like people really "don't care", because there is rarely a response (thanks Beegle, I really >do< appreciate the inputs). It's not like I'm looking for a pat on the back, but it would be nice to know that people are interested! I know when somone busts their butt on their car, I sure like to let them know that it's worth their while.

That's what still gets me about this group - if it was the Maverick group, people would be all over it. Sometimes it seems very odd out here. I'll still keep a pictorial history as I go, but if nobody cares, I won't waste their time.

Chris

dave1987 · « **Reply #55 on:** May 12, 2009, 08:40:03 AM »

Continue to post pictures! I LOVE going through project threads on everyone's cars, which is what prompted me to take pictures of mine. There are things I don't take pictures of though because I feel like it's not worth the time to do it, as you stated.

I was actually just about to reply just before you posted that last bit, but it said someone else had posted a reply while I was writing my response.

You car is coming along AMAZINGLY WELL! It makes me jealous and wonder why in the world I didn't pay as much attention to detail when I did my ball joints, since I had the front end taken apart anyway. I guess it will have to wait until I replace all of the bushings....

Keep up the great work Chris, I'm loving the whole thing

If I only lived closer, I would be happy to come over and help.

popbumper · « **Reply #56 on:** May 12, 2009, 08:52:54 AM »

Geeze Dave, I wish ALL of us lived near each other - not to sound campy - but it would be NICE to be able to take all of our collective experience and put it together. Would it be GREAT to have a "Pinto Restoration" shop? Yeah - I'm dreaming. My wife thinks the thing will never get done. I beg to differ.

Thanks for posting!

Chris

dave1987 · « **Reply #57 on:** May 12, 2009, 08:58:25 AM »

I'm with you on the Pinto Restoration Shop idea! If things continue to go as they have been for me, I may be moving down to Arizona since I am getting tired of everything going on here in Idaho. I'd be closer to more Pinto members and Knotts would be realistic.

When I own my own home with a garage, it WILL be a Pinto restoration shop!

78txpony · « **Reply #58 on:** May 12, 2009, 12:10:21 PM »

I am glad i was able to come help out a little bit. If it wasn't for the date I had that night, i would have stuck around to see the car move under its own power!
Attention to detail takes a LONG time - my Olds has taught me that. Freshen up one area, and everything else looks like s*** on a white rabbit... :reek:
I wish i repainted my front end components when i rebuilt it back in 2002, but I guess it will have to wait until the next time... I never thought I would try to restore the car. To me, it is still just a cool-weather daily driver...
I have to say those AFTER pics look great, and it was not because of the photographer! :smile:
:police: The city gal will be impressed - you know she will want a ride! :lol:

I am glad that big accomplishment is done - now you can move on to the next! :drunk:

popbumper · « **Reply #59 on:** May 12, 2009, 12:55:15 PM »

I'm at home for lunch right now, heading back to work. Of course, when I got here, I took her for a quick ride. It's SO great to be "up and running" again.

What's next, Rob? Retrofit of factory A/C :hypno:?

Chris

News:

Current Classifieds

Author Topic: Popbumper's '76 wagon - update (Read 80480 times)

75bobcatv6