BUILD-OFF CHALLENGE: Dirty Cossack's Build Options

[JoeDees]

I had every intention of making an introduction video, but I found that I had ruined my wide angle lens trying to film some cool shots of grinding. So while I'm waiting for the new lens to be delivered, I will go with this novel:
I bought the car about a year ago with the shortsighted intention of throwing it back together and having a driver until its turn came for rustoration. I bought the car and a carload of parts from a guy in Dallas who did some really shady work and an incredible job hiding other rust; magician style he distracted with his obvious poor work. The drivetrain was out of the car and registration said it had been sitting for 12 years, so I don’t know what made me think I could get it driving in a month… Soon after buying the car, my daily driver VW went down and needed a bunch of work and Uncle Sam gave me orders to move 800 miles. I fiddled with the 914 now and then, mostly just probing for rust, but focused my attention on prepping my other projects and VW for sale, knowing I could only bring one car with me and it had to be rolling so I couldn’t really tear into it. I’ve been here in the new, much smaller shop since June and have been slowly tearing into the 914 between honey-do new house projects, new job training, and getting the new shop in order.
As we sit now, the car is on jackstands with the rotisserie acting as additional bracing, the engine and trans are under a workbench, the bigger pieces of the car are using the extra bedroom (the one my wife says needs to be vacated when we get pregnant) and others in boxes in my closet. Tearing the car down, I’ve found almost everything worse than I expected. The gas tank is pretty nasty with rust, all 4 calipers are locked up and the wheel bearing grease congealed. Removing the bumpers I found some evidence of prior damage and filler. Further probes into the longs found some rust on the driver side, and the passenger side nearly shot. The hellhole was a known problem, and turned into a chasm. I haven’t really dove to much into the floor, but found rust around the firewall and under a seat mount. The good news seems to be in a relatively dry trunk and pedal area.
My project’s Big 5 jobs are: 1) Rust repair. 2) Body work and a complete repaint. 3) Complete overhaul of the brake system, bearings, CVs, getting the window to work and stuff like that. 4) Engine rebuild. 5) Customization: wart removal, interior work, and an attempt at making custom made bumper tops.
In this build off challenge I face multiple fronts of challenges: 1) I grew up helping my Dad fix VWs, redid a Triumph Spitfire in my early 20s with his help, and have done numerous small projects over the years, but this is my first full rustoration on my own. 2) I have a severely limited budget. I am active duty Army, and everybody knows that NCO paychecks leave much to be desired. 3) I’m often short on time. My current assignment is as an instructor requiring me to work 10-12 hour days and 50-60 hour weeks. 4) I have a bum knee that makes it almost impossible to crouch and am fighting a shoulder issue that makes working overhead painful (praying for no surgery). 5) Nothing but the windshield and fine machine work like the heads and crank will be farmed out, I’m doing this on my own.
Well this is where we are starting, and honestly, who knows where we’ll end up. I haven’t really decided on color, engine, or upgrades, though I’m leaning towards keeping the 1.7 Liter Fuel Injection unless a good deal on another engine arises. I’m also thinking of keeping the car black but going minimal chrome, but who knows what the good idea fairy will deliver. I hope you enjoy the journey as much as I do.

[JoeDees]

I guess it's as good of a time as any to make the announcement: This build may be on a long-term hold...

Long story short: Our dog Muttley (not the greyhound) got sick and spent a week at the vet. She was first at one vet who then recommended us to another larger facility in Tucson. After several negative tests for Valley Fever a doggy neurologist got involved and x-rays, CT scans and a spinal tap finally found that she is suffering from meningitis. Treatment involves a long term regimen of steroids. She finally came home yesterday and her prognosis is good for recovery. BTW, a dog high on a fentanyl patch is funny. Anyways, the experience has cost us a little over 2 months pay, resulting in the near draining of our primary (emergency) savings account, selling some stocks from our long-term (future house downpayment) savings, and sadly the draining of my 914 account, all with more bills for the medicine on the horizon. So I have no money to really continue, though I guess I can weld until I run out of gas/wire, grind until the disks are dead, etc. But as far as buying anything, I'm done until we replenish the savings account. I'm also thinking it best to wait until the dog recovers some before I start getting loud in the garage again. I've got some stuff to do to the 914, but most likely I will finish the metal work, spray some of the cheap primer over the bare spots and prep the car for next year's move since I won't be able to paint it for a while and it will be easier to paint at my old Kentucky home anyways.

The stress and hardships have also exacerbated the above hinted at issues with the new greyhound. The other dog's illness put a serious dent in the critical time period for the proper cat-dog intros and getting them to live together. The sick dog has also affected the greyhound's socialization with the family and she is extremely jealous of the necessary attention the invalid is getting and won't let the already non-eating dog eat. This is why my wife wants to exchange her for a more cat friendly and laid-back greyhound. I want to keep working with her, but convincing the wife to do so is hard.