Author Topic: Popbumper's '76 wagon - update (Read 81353 times)

pintogirl · « **Reply #90 on:** July 11, 2009, 10:18:27 PM »

When I stripped my first Pinto, I had intentions of using it's dash for my good car. The only thing is, the vin number is in the dash. What did you do to solve the vin number problem? Are you going to drill out the rivots and re rivot the correct vin into your "new" dash? I was thinking of doing it that way, but you have to make the "rosets" in them and hope that a LEO doesn't see that it has been tampered with. I know that a Pinto shouldn't draw to much attention as far as that goes, but you never know!!

popbumper · « **Reply #91 on:** July 11, 2009, 11:46:05 PM »

That would be the only way to assure that everything was legal. Since I have a valid title and am the owner, there should be no problem.

The 1978 dash VIN plate is also invalid, because in Texas, once a car has been sold off to salvage, it can never be resold to the public. The junkyard who sold me the dash never even mentioned it.

Chris

78txpony · « **Reply #92 on:** July 13, 2009, 12:11:43 PM »

Looking good, Chris - smells like progress...

I see lots of painting in your near future!

smallfryefarm · « **Reply #93 on:** July 13, 2009, 03:25:49 PM »

It really is looking good Chris. I dont envy your work, i have a 65 mustang down to the bone going thru the same things. Its not the kinda of work i like to do. But it will one day have its rewards. Keeper up.

popbumper · « **Reply #94 on:** July 13, 2009, 04:43:22 PM »

Quote from: 78txpony on July 13, 2009, 12:11:43 PM

Looking good, Chris - smells like progress...
I see lots of painting in your near future!

Thanks SmallFryefarm. It's all for a good cause, glad you know what it is like.

Hey Rob, painting started last night at 8 PM - you know, when the sun finally started going down and it was still 95 degrees. Got one shock and the bumper insert mostly done, and quit about 9 PM. Plan to do a little more tonite!!

Chris

discolives78 · « **Reply #95 on:** July 25, 2009, 02:20:00 PM »

I'm surprized it's not up on a 'rotisseire' yet, Chris.

Lots done, and lots to do.

You've got your hands full of small pieces :laugh: I'd say you're doing a pretty thorough restoration there!

Good luck...

Chuck :afro:

hellfirejim · « **Reply #96 on:** August 06, 2009, 06:58:24 AM »

Question on the windshield pull. What advice can you give as I will have a 77 donor car that I want the windshield to put into my 75? Pulling the old without breaking and such. Any thoughts would be welcome.

jim

75bobcatv6 · « **Reply #97 on:** August 06, 2009, 09:16:49 PM »

take a guitar string pref a D string.(i play guitar) its the 4th largest string you can get. get that through the old silicone or what ever they used to fasten the window down and just Slowly use it like a saw and work your way through that adhesive. (if its Adhered that way) Gl jim

popbumper · « **Reply #98 on:** August 06, 2009, 09:58:48 PM »

I used a special knife I bought at the glass store for just this purpose. It is like a safety knife with an extendable blade, and can cut very deep. I probably did not need it, but I chose it since I have >no< experience pulling windshields.

Man, another 4 weeks and it should start cooling down. I CAN'T wait, 'cause I want to get cracking on the car again!!!

Chris

popbumper · « **Reply #99 on:** August 31, 2009, 10:21:06 PM »

No pics tonite but stay tuned. SEASON TWO of "Restore my Pinto Wagon" began tonite; the wether is FINALLY starting to cool down, high today was only 87, and for Texas, that's AWESOME. Spent about 1.5 hours tonite outdoors doing some much needed teardown....

....with the official removal of the original dashboard. Holy moly, getting a dash out is a wonderful thing, and I can't wait to finish it; I have another dash out of a '78 waiting in the wings and being painted/populated for the great swapover. Taking a look at the harnesses and such, all looks pretty good, though of course the pedal hangar and associated brackets are quite rusty (again, no worries, I have sandblasted and painted a replacement set on the side)!! My heater box was chock full of mud dauber nest/insulation/dead leaves, it is finally clean again, though needs carefully cleaned up/repainted/restored.

Once the dash is done, the headliner goes in, and the car moves into a garage...where I will pull and replace the rear end with a better restored one, pull the motor and replace the inner fender, and get my interior done. This Fall/Winter should be a VERY active time and I plan to get a lot done.

I am stoked. Fall is ALMOST HERE!! Again, sorry no pics tonite, I took them but they need resizing and I have to do it.

Chris

78txpony · « **Reply #100 on:** September 01, 2009, 11:38:11 AM »

Take extra pictures of the heater box for me - I am curious to see what it is like. Mine has never been out, but EVENTUALLY I need to replace those rotting heater hoses before they decide to blow...
Maybe I can stop by some time and look at it.

Isn't this weather great? I was out for an hour yesterday sanding & cleaning a sway bar and never sweated a drop!!

Tonight I will paint the bar with POR15...

popbumper · « **Reply #101 on:** September 01, 2009, 02:12:34 PM »

Yeah Rob - you can imagine my excitement when I got home last night - after dinner I disaapeared, I think the family thought I was alien abducted

.

Got pics of everything. My heater box needs rebuilt (has a hole in it....and it's NOT a stock P/N for my year car, probably because of the dealer A/C). The dampers are all rusty, and gaskets need to be replaced (I will cut my own). Kinda think I will stop at the firewall and leave the heater box and motor intact (that is, attached). No real reason to remove anything back there. Rest of the floor will get the Dynamat treatment before being recarpeted.

Visited with the local upholstery guy at lunch - I'm gonna pull the car over there in a week or two and get a new headliner (about $300 installed). Gonna get color matched "close enough" - don't want to spend $229 on an original, and can't put the windshield back in until the headliner is replaced.

FUN, FUN. More later - you need to come by and inspect the process.

Chris

popbumper · « **Reply #102 on:** September 11, 2009, 08:49:59 PM »

Update for September 9th, 2009

It has been an interesting Summer. Forget that, it's been TOO hot to do anything - and yes, the time I have waited for is here. About a week ago, we had a reprieve in the weather, and the weather is promising to get cooler - SO - time for another season of car work.

On tap? Something that has been planned ever since the windshield was removed - DASH REMOVAL AND RESTORATION.

Photo 1 shows one step in removal of the dash. This is accomplished by loosening four screws at the base, separating it from the steering column, and loosening 6 screws beneath the rubber seal where the dash meets the windshield.

Photo 2 shows the loosened dash, ready to pull away from the car once theharness and control bezels have been removed

Photo 3 shows the dash out, and the undersides exposed. Note the heater box with a hole in it, the loose and hanging underdash A/C blower unit, the loose harness, etc. There are quite a few things to address here!

popbumper · « **Reply #103 on:** September 11, 2009, 08:57:29 PM »

As said, having the dash out allows for a great deal of attention to much needed items, as well as a thorough inspection of everything. Focus one: HEATER BOX

Picture 4 - Fall began EARLY in my heater box, stuff with leaves and debris from years past, including three large mud dauber nests. It's no wonder the fan would never turn on. This mess will be vacuumed out, and everything will be carefully washed/scrubbed.

Picture 5 - with the heater box opened up, the internals are exposed. The hoses and heater core look fine, but the "mix door" is well rusted with a deteriorating surround. This door will be replaced with a NOS unit.

Picture 6 - The outside of the box turned over; the metal divertor plate is rusty, and the gasket is well worn. The box itself is cracked, and there is a hole in it where the mount bracket used to be. Blink77 has kindly stepped forward to donate a solid replacement.

popbumper · « **Reply #104 on:** September 11, 2009, 09:09:47 PM »

Moving right along, the pedals and pedal hanger beg for attention, having originally been installed at the factory as natural metal that has long since developed a coat of rust. Part of this rework is also to convert the manual brakes to power brakes; the RESTORED unit is for a power brake setup, and is different from the original.

Photo 7 - The pedal hangar removed, with pedals, front view. Not a lot to talk about here, but if you have not seen one out of a car, here it is.

Photo 8 - same hangar from the rear view. The rear of the bracket bolts up to the firewall and interfaces with the master cylinder and clutch cable, where applicable.

Photo 9 - This pedal hangar (a donor from a '78 with auto tranny and power brakes) was carefully disassembled into pieces, sandblasted, painted with POR-15, then a metallic topcoat, and reassembled. Pics of the pedals installed later.

Photo 10 - Hangar reassembled minus the pedals.

popbumper · « **Reply #105 on:** September 11, 2009, 09:24:25 PM »

With the heater box started, and the pedal set near restored, we get to one of the MAIN reasons I wanted to pull the dash. If you have kept up, you saw the rework of the cowl hole that I did a few months back. The extent of the damage at this area was worse than I though, but not as bad as it could have been since it has now been arrested.

Picture 11 shows the corner of the dash where the leak existed. Note the water leakage as it had creeped into the pillar/firewall interface. The rust here was pretty bad.

Picture 12 - Not only had the rust affected the interface, but had crept up around the pillar and into the rain gutter weld as well. This required some original body seam sealer removal, which showed rust underneath.

Picture 13 - Using a wire wheel, the area was carefully ground down on all surfaces, getting the pitted metal shiny. Note the small holes at the pillar; had this been left to itself, the pillar would have disintegrated, pulling the roof away from the firewall. Wow!!

Picture 14 - The whole area sealed with POR-15. I have yet to add POR-15 putty to this area, and fill/sand/prime before repaint.

That's is for now. The next few weeks promise to be most interesting as the dash is replaced (as fully restored), power brakes are installed, and the car goes to the shop for a new headliner. NOT SHOWN - I am also in the midst of restoring the steering column, with everything being repainted and the mechanicals cleaned/adjusted. Have fun, hope you enjoyed this update.

Chris

pintogirl · « **Reply #106 on:** September 11, 2009, 09:45:33 PM »

Chris, are you going to be submitting all this to the magazine? I think it would be an excellent build article!! I know I am following this thread because I plan on doing the same thing with my car. I'm not to thrilled about disconecting all the wiring under the dash, but I'm sure if I forget where something goes, I can always ask you or someone on here!!!

In other words, I really like your thread on this project!!!

Well done!!! Well, not done, but..... you know!! LOL

popbumper · « **Reply #107 on:** September 11, 2009, 10:00:03 PM »

Hey Becky!

Thanks for the kind words. This is a lot of work, but there is plenty being learned. I have been taking photos I have not shown here so that I can write specific articles and submit them to the magazine as things get done. I know Matt is busy - I already have an article out to him called "What they don't tell you about Pintos" that talks about some of the unexpected challenges and pitfalls the unsuspecting Pinto owner goes through when restoring one!

Again, thanks for reading, I hope these recaps help someone along the way!!

Chris

pintogirl · « **Reply #108 on:** September 11, 2009, 10:17:47 PM »

Quote from: popbumper on September 11, 2009, 10:00:03 PM

Hey Becky!

Thanks for the kind words. This is a lot of work, but there is plenty being learned. I have been taking photos I have not shown here so that I can write specific articles and submit them to the magazine as things get done. I know Matt is busy - I already have an article out to him called "What they don't tell you about Pintos" that talks about some of the unexpected challenges and pitfalls the unsuspecting Pinto owner goes through when restoring one!

Again, thanks for reading, I hope these recaps help someone along the way!!

Chris

LOL It's Kim, but that's ok! I don't mind being called Becky!!

I can't wait for the next magazine!!!! Looking forward to your article!!

popbumper · « **Reply #109 on:** September 11, 2009, 11:09:58 PM »

Oh BOY, my bad, very sorry..... :rolleye:

Thanks regardless, Kim, I appreciate the patience!

Chris

popbumper · « **Reply #110 on:** October 12, 2009, 10:06:55 AM »

"Semi-update" for October 12, 2009

"Rain, rain, go away"

. Unlike last Fall, which had literal WEEKS of beautiful weather, this year we went directly from Summer to Winter. It has been cold (for Texas) - about 55 degrees every day, cloudy, raining all the time. Of course, with the car sitting in the driveway, I have been unable to get hardly ANYTHING done. I did buy a car cover, so at least I am not getting soaked anymore.

As soon as I have more to post, I will. The car is slated to move to a buddy's shop, but until I get the driver's firewall area done (again, can't due to rain), I can't move the car. Right now, I am still in the midst of restoring this area, putting down some "FatMat" and "Second Skin" sound dampeners (in place of the original decaying jute material). The vent and windshield wiper motor have been restored, and everything is going over to a power brake setup.

More later, with pics. They are telling us sunshine this weekend :cheesy_n:.

Chris

78txpony · « **Reply #111 on:** October 13, 2009, 12:01:36 PM »

Quote from: popbumper on October 12, 2009, 10:06:55 AM

I did buy a car cover, so at least I am not getting soaked anymore.
Chris

Uhhh, Chris, the car cover goes on the CAR, not you! :lol: You need to reread the instructions.. . :read:

Have you installed a bilge pump in it yet?

:lol:

This weather is totally different than last year's... However the last electric bill of $48 was a welcomed treat. My Pinto project is on hold due to rain also. The box o' parts is ready though...

popbumper · « **Reply #112 on:** October 13, 2009, 04:36:04 PM »

Hey Rob:

I will be more careful with my wording

. The car is nice and dry - for a change - as am I.

This weekend is "install sound deadening material/reinstall pedal hangar/get the power brakes in/restart the car" weekend. If you are around, you may want to see/share in the festivities.

I should have bought a finished car - shutting my mouth now :reek:.

Chris

78txpony · « **Reply #113 on:** October 13, 2009, 05:25:31 PM »

Sounds like a productive weekend if the weather is right...
Saturday I am going to an all-day all-Olds show in Ft Worth, complete with nightly drag racing. IF you want to go, let me know and you can drive the 86 - I am taking the vert...
Sunday is up in the air - the ladyfriend is robbing me of time lately... :hypno:
I should be able to stop by for a short time, just to make sure you are working on your car.....

popbumper · « **Reply #114 on:** October 18, 2009, 10:04:10 PM »

Update for October 18th, 2009

With the weather finally cooperating, much was accomplished this past weekend. For those who have been watching, the firewall area around the drivers area has been in heavy work, both preparing for new insulation/sound deadening material(s), as well as restoration of the brake/clutch pedal assembly, and swapover to power brakes. This has been a huge project, I probably spent 10 hours in the car this weekend alone.

On to the show - Pic 1 shows the installation of "FatMat" sound deadening material to the firewall area. This material dampens vibrations, and is a good heat/cold block as well. It has a very sticky backing, and once on, is virtually impossible to peel off. This material was carefully cut to the firewall, and up around the cowl underside.

Pic 2 - on top of the Fatmat, I am adding a vinyl/foam barrier for sound reduction. This material is made by "Second Skin", and will replace the old, scrungy jute/rubber firewall pad. Now, in order to "fit" it properly. I used the original firewall jute pad as a guide for cutting holes in the proper places; note them side by side.

Pic 3 - Here, the small but important "gas pedal plate" has been added to the material, just as it was in the factory pad (placed in the pad, and gently "hammered" so that it grips the pad). Now, with some careful cutting, the pad will be installed to the firewall using spray contact cement.

pintogirl · « **Reply #115 on:** October 18, 2009, 10:08:29 PM »

Very nice!! I like the pics. Specially the side by side. Sure shows a difference on how much nicer the new is!!!

Great update!!!

popbumper · « **Reply #116 on:** October 18, 2009, 10:14:41 PM »

Continuing on.

Pic 4: Once the pad is placed at the firewall, everything is glued and carefully trimmed to the surrounding mechanisms. All items which are "in the way" need to be accounted for, including the windshield wiper motor, which is removed and repainted. Adjustments are made, the layer is not perfect, but far superior to the factory mat.

Pic 5: With the pad and mat work finished, the assembled brake/clutch pedal hangar can be reinstalled to the firewall. There's a lot of work to do here; all braces/brackets must be realigned, the pedals must be linked to their proper mechs, everything must be tightened down. I found that the clutch cable length had to be adjusted, and for some unknown reason, the clutch pad sits higher than the brake pad. I also reinstalled the freshened gas pedal assembly; I sure wish I had a new "pad" to match the new brake and clutch pads.

Pic 6: Here's a bottom shot of everything looking up from the floor. Note how clean everything is - it looks SO much batter than it did when I first got the car. NOTE the steering column has not yet been attached (nor the rubber "seal" installed at the firewall) and needs a good cosmetic restoration itself. Given the condition of the original plastic parts, most of them are being replaced.

popbumper · « **Reply #117 on:** October 18, 2009, 10:23:16 PM »

And finally - with the drivers' side firewall nearly complete, I have yet to install the power brake setup in the engine compartment, readjust the clutch cable, and get her fired up again. For better or worse, I figured while I was at the firewall, I need to go "all the way".

Pic 7: Inside the engine compartment, I located the heater hoses, cut them, and bypassed the heater core. Taking out the four bolts that hold the blower motor to the firewall. the whole heater box assembly nicely slips out of the car in one piece. Look at all the lovely surface rust and general filth - I promise you, in a short time it will all look next to new.

Pic 8: This shows the next are that will be tackled, first with FatMat, then with sound deadener. You can see the dealer A/C box as it sits on the tranny hump, waiting for reinstallation .

You know, I have been into this for over a year now, and I am amazed at the amount of work it is. That's not a complaint; I suppose I could have "stopped myself down" from doing so much, but I am driven to do as much as I can. This car will drive like new when finished, look better than factory in many respects, be mechanically new, and be quieter to boot. I >do< get weary of it from time to time, but I continue on, hpoing to cross that next bridge...

NEXT: Firewall completion THEN dash rebuild and reinstallation . It's gonna be beautiful....!

78txpony · « **Reply #118 on:** October 19, 2009, 07:51:04 AM »

Great progress! I need to stop by this week to see it for myself.
How did you make those nice holes int he insulation mat? Looka like a punch of some sort - very pro looking!
I am starting to wonder if I might be able to change those heater hoses afterall. The heater box looks somewhat easy to get out (but of course you yanked the dash off first...

BTW, out of all the chances in the world, I got to race my 442 against a 76 Pinto bracket racer on Saturday at the drag strip... He was faster but I won due to him leaving before the green light!

We had lots of fun there and my 442 even got the People's Choice trophy!

popbumper · « **Reply #119 on:** October 19, 2009, 10:33:38 AM »

Rob:

Love the story on the 442 - like you said, what are the odds against a Pinto? What did they have in it? Congrats on the award as well - I'm sure that was a big thrill!!

Don't worry, we'll whittle your Pinto down to the bone and restore it after I learn how to do all this stuff :lost:. Ya, right. :lol: At any rate, I placed the old pad over the new stuff, traced the patterns, then hand cut the holes with a long utility knife and/or X-ACTO blade. The spacing was not EXACT but it was close. Funny stuff is, most of this effort gets "buried" by the carpet, so it need not be perfect, but I am trying to at least be sure it is not sloppy.

Also - your heater box should not be too difficult, even with the dash in place. The hard part will be getting off the clips that hold the clamshells in place. My core was solid - testament to being a southern car - so no need for me to replace it. Of course, I took your advice and thought it a good idea to go after hoses, since everything was right in front of me.

Thanks for watching and replying - I knew I could count on you

. Said it before, will say it again - I get so few comments when I put this stuff out, I wonder if it's even worth posting. Maybe I'll just catalogue all this stuff and put together a restoration "document" of some kind.

Chris

News:

Current Classifieds

Author Topic: Popbumper's '76 wagon - update (Read 81353 times)

75bobcatv6