January 2007

I started the installation of the front brakes by installing the master cylinder.

This shows the other side of the master cylinder and the wiring for the low fluid indicator light.

Here's the brake fluid reservoir.

This shows the flex line attached to the hard line from the master cylinder.

Next, I installed the brake dust shield, held on by (3) bolts.

The brake disc/front hub is installed next. Remember to regrease the (2) bearings before installation.

Finally, installed the grease cap. This is all of the front brake work for now. I'm sending the brake calipers out to be rebuilt.

I started working on the interior today. This is some of the reference shots.

Another reference shot.

Another reference shot.

Another reference shot.

After removing the seat rails, I removed the glue from the firewall.

I used 3M general purpose adhesive cleaner. The best way to use this product is to soak it for several minutes, then wipe with a clean rag. The glue wil rub off, with a lot of elbow grease. In some sections, I had to do it several times.

Next, I removed the floor tar. I used an air-hammer to get up under the tar. Next, I removed the seam sealer in the corners. After removing this seam sealer, it exposed a rusted section of the firewall, behind the passenger's seat.

I created this batch section.

This shows the section cut out.

After spending about 6 hours cutting, trimming, welding, bondoing, then spraying with primer, this is the final results. Before painting, I'll spread some seam sealer to fill the cracks.

I started the installation of the gas tank by replacing the fuel lines with new ones.

Next I installed the long strap that holds the tank in. It's held on by a nut, attached to a bolt that is welded to the firewall, underneath the drain lines. This strap holds the threaded nut.

This is the short strap that attaches to the panel between the gas tank and the front trunk. It's held on by a bolt. This strap holds the non-threaded nut.

I replaced the original carpet pads with these neoprene ones.

This is what the gas tank looks like after refinishing.

This shows the return line (small diameter) and the in-tank fuel filter, on the pressure line (larger diameter).

Next, I installed the filler neck. There's a gasket between this filler neck and the gas tank.

This shows both hard fuel lines installed.

Next, I placed the gas tank in position, propped it up and installed the new fuel lines. Make certain that the fuel lines are long enough to provide you the ability to lift the tank up.

This shows the tank in place. There are 2 rubber bumper pads, one at each side, that supports the gas tank off of the side walls.

Make certain that the overflow drain tube is installed. The other end of this lines goes through a hole in the floor, underneath the gas tank.

Next, I installed the gas tank fuel sender electrical connection. This also shows where the expansion tank attachment points are.

Next, I installed the expansion tank. This tank is held on by 2 bolts, one one either side.

There's a small rubber hose that connects between the expansion tank and the filler neck.

Next, I installed the plastic cap, underneath the straps, and the bolt.

Finally, I installed the evaporator tank. There's a small rubber line that connects to the expansion tank.

Here's the clip that holds the water bottle for the windshield sprayers.

This shows the water bottle installed.

The final step was to connect the fuel evaporator. This shows where the hoses from the engine route back to the evaporator.

A nice overall view of the tank installed.

This shows the piece that is mounted to the car that holds the front hood bracket. This piece is used to adjust the height of the hood at the rear.

This shows the front hood bracket installed.

Here's a shot of the hood. I painted underneath, but only primered to outside. I'll finish it when I complete the body.

The hood is held on by these 2 bolts on either side.

Here's a shot of the latch that is attached to the front of the hood.

I also installed the springs.

Here's a shot of the hood open.

And, here's a shot of the hood closed. I still have to do the final adjustment, which I'll finish when I do the body.

Here's a shot of the carpeted false floor in the front trunk.

This is where the horn attaches to behind the bumper.

The horn is held on by a lock washer and a bolt. The factory also suggests a 'shake proof' washer, I made one using neoprene.

These are the wires that connect to the horn. There are (2) black/yellow wires on driver's side, but only (1) black/yellow on the passenger side. The other wires are (1) brown on each side.

This shows the horn attached.

A nice wide shot of the front section.

I started the removal of the pedal cluster by removing the clevis pin (for the clutch cable) and the brake cable from the pedal cluster. I also removed the wires from the brake light switch.

Next, I removed the (2) nuts on the floor and the (2) nuts from the brake master cylinder. This shows the crud and garbage that collects underneath and around the cluster.

This shows the pedal cluster removed. I'll rebuild it using the new bronze bearings, instead of the original plastic ones.

Another shot of the pedal cluster.

After removing the sound-deading tar, I found this area rusted out. BTW, I used an air chisel, hand chisel, screwdriver and scraper to remove the tar. I only used the air chisel in the large section, then the manual tools in the corners and the ribbed areas.

This shows the patch I made.

Here's the section after I cut out the rust, welded in the patch, small amount of bondo, sanding, then rust proofing primer.

I removed the factory seam sealer to check for any other hidden rusted areas. After I primered this area I added the new seam sealer.

This shows the rear section primered and seam sealed.

This shows a nice wide angle of the driver's floor.

I taped off all of the bolt studs, wiring harness in the center tunnel and any of the voids in and around the center tunnel. This is the driver's front section, where the pedal cluster goes.

Here's the section where the driver's seat goes. I wasn't able to remove the cable from the hand brake handle, so I just taped it up and painted around it.

This shows the front section of the passenger side.

A shot of the rear section of the passenger side.

This is a wide shot showing how I covered up the dash and the wiring harness.

A shot from the driver's side.