Cary's 73 1.7 Rustoration Thread Options

[cary]

How does this deal work?
There is a light metal frame right at the base of the sail panel.
Just tacked in there with 4 wimpy welds, then a pile of seam sealer.

[cary]

So decided that I would start tearing into the passenger side wheelhouse.



Start drilling out spot welds............... (IMG:style_emoticons/default/biggrin.gif) (IMG:style_emoticons/default/biggrin.gif)



Just when I think I can remove the inner wheelhouse longitudinal.
I find these tack welds way up at the end of the wheelhouse.
Not good............ I tried chiseling them out.
(IMG:style_emoticons/default/evilgrin.gif) (IMG:style_emoticons/default/evilgrin.gif) Poked a couple holes with the chisel.

[cary]

Got it out. Cut it into three pieces to get it out.





Made a mess .............I'm thinking I went thru 6 cutting disks.

[cary]

Test fitting a couple pieces. Inner needs some trimming to get it to fit against the trunk wall.

[cary]

Now in lies the big question. How do weld back in the top of the
inner wheelhouse long against the rear trunk.
I'm thinking arc welder turning way down with a small rod?

[cary]

Uhhmmm, Cary. Does the super in law do house calls? You are one lucky guy.

In answer to your first question. Yes.
He's heading out this am to help lay a Pergo floor.

I hate to think of the day when he wont be out there helping me. (IMG:style_emoticons/default/sad.gif)

[worn]

Now in lies the big question. How do weld back in the top of the
inner wheelhouse long against the rear trunk.
I'm thinking arc welder turning way down with a small rod?

I would turn the mig up high and then make sure that you concentrate the heat at the larger metal. That's the problem with mig welding, because heat and fill are hard to separate. Stick is pretty similar in that regard. It sounds like you are worried about penetration at the long. Try a test piece of the same thickness. With your new torch I bet it works.

[sixnotfour]

plug weld from the shock tower side

[cary]

I would turn the mig up high and then make sure that you concentrate the heat at the larger metal. That's the problem with mig welding, because heat and fill are hard to separate. Stick is pretty similar in that regard. It sounds like you are worried about penetration at the long. Try a test piece of the same thickness. With your new torch I bet it works.

I don't think I can reach in there ....................
But I haven't tried.

[cary]

plug weld from the shock tower side

No access. Its backs up to a closed in cavity. The shock tower hole.

[cary]

TIME OUT

Oldest son came up from Eugene for Easter. The coolant leak we've been chasing finally let go. (IMG:style_emoticons/default/sad.gif) (IMG:style_emoticons/default/sad.gif)
Its on a 2002 A6 2.7T.
At first glance I'm hoping its a hose. But it's probably the gasket on the water pump. It has about 60k on it.

I got lucky. He and my daughter in law just drove to SF for spring break. Took about 16oz on the way down. And about 16oz on the way back. I was still thinking it was a weeping hose connection.

It let go right here at the house. I did the timing belt service myself about 60k ago. We'll see if it was my workmanship or a failed component.

I'm going to the shop after work to pick up the leak detector lamp kit and the HF camera.

[cary]

Water pump gasket let go.
And I can see a hairline crack in the impeller.
Might as well throw in a new cam timing belt while I'm in there.
We've gone 65k since the last one.



Yippy, skippy .................

At least I'll have Pelican 911 Boards burgers and beer tomorrow night.

[cary]

All cleaned up and waiting for a hose from Audi.
One of those while I'm in there. Must be Jeff Gamroth rubbing off on me. 4 hoses, $250.

So I'll head out to the shop and get back to work. I'm going to put a new jack point on the white car first. When I pulled the rocker panel I found it packed with sand. (IMG:style_emoticons/default/sad.gif) (IMG:style_emoticons/default/sad.gif)

[cary]

Oh yeah.
Workmanship investigation.
I used RTV on the gasket. Which was the preferred practice at the time. Now its a no no.
Looks like the gasket broke down over time.
Water pump impeller had a hair line crack too. So timing was actually good.

New preferred method is dry. I just cant bring myself to do that on a water pump. So I discussed it with my 911 Yoda (Steve Weiner).
He would use a product called Gasgacinch. That's the direction I'll go.

[worn]

Oh yeah.
Workmanship investigation.
I used RTV on the gasket. Which was the preferred practice at the time. Now its a no no.
Looks like the gasket broke down over time.
Water pump impeller had a hair line crack too. So timing was actually good.

New preferred method is dry. I just cant bring myself to do that on a water pump. So I discussed it with my 911 Yoda (Steve Weiner).
He would use a product called Gasgacinch. That's the direction I'll go.

I have always like permatex non hardening. Super sticky and makes a mess that tells you that you have achieved something. Gasgacinch is pretty nice too and far less messy.

[cary]

Finally got it finished.
Replaced all the hoses, except the $200 upper one.
If it wasn't for bad luck I wouldn't have any.
That hose let go three days after I finished it up.
Damn it ..................

Glad they hadn't taken it home.

[cary]

Finally back to the shop ................
And back to work (play) .........................

[cary]

Next order of business.
Measuring the inner/engine long.
I'm using the hinge studs as a point of reference.



It was about a 1/4 off ..........................

[cary]

So I had to fiddle with the top end next to the back shock tower.



Still didn't fit. Had to recut the flanges.

[cary]

Now it matches the drivers side.



Here's the virgin divers side.



Now the passenger side after I finish tinkering.