BUILD-OFF CHALLENGE: Michigan Build, Garland, Never ending project, 8/2023 reinstalling headlamp housings Options

[Garland]

Slow, and easy......don't want the bit to heat up. Just shaving my way along.

[jmitro]

yea, get a real hole saw.

[76-914]

I can't bear to look.......That wood bit could snag and break the lens real easy.

You might want to try a hole saw instead.

Good luck.

Amen, but the pilot bit will want to pull into the plastic very quickly as it is a std bit. Plastic drill bits have a very acute angle (135 degree IIRC) which keeps it from pulling thru too quickly resulting in a broken plastic piece. So yes, a hole saw is best but pre-drill the pilot hole with a bit made for plastic or recess the pilot bit enough so that it doesn't bite into the material too early. Aircraft Spruce sells these bits if you can't find them locally. (IMG:style_emoticons/default/beerchug.gif)

[Garland]

Start to finish 10 minutes per cut. Shaving off just a layer at a time. Works even when overlapping a prior cuts. If you cut to fast, you will see the plastic turn white. You want to cut, not melt.
Then saw, and file. Light sand, and polish.
Mounting and wiring next.

[whitetwinturbo]

(IMG:style_emoticons/default/popcorn[1].gif) (IMG:style_emoticons/default/popcorn[1].gif) (IMG:style_emoticons/default/popcorn[1].gif) (IMG:style_emoticons/default/popcorn[1].gif) (IMG:style_emoticons/default/popcorn[1].gif)

[Darren C]

Too scary for me... ;-)

Well done!

Now, how you going to seal water out?

[Garland]

(IMG:style_emoticons/default/idea.gif)

Thinking brutal, but can make a mess. So working on rubber seals.
From scrap 914 weather striping, and seals.

[mb911]

Looking good interested in how the rockers look completed now that they are textured and fit against the flares.. I might go this way versus using the fiberglass rockers I have currently.

[whitetwinturbo]

REALLY nice lighting (IMG:style_emoticons/default/beer.gif) (IMG:style_emoticons/default/beer.gif) (IMG:style_emoticons/default/beer.gif)

[Andyrew]

Awesome headlight solution!

But... Why did you mount the headlight cover upside down?

[raynekat]

Those are definitely some "mad" skills you have my Man.
Well done.
You are in a league of your own.
Nothing like this has ever been done.
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[Garland]

Awesome headlight solution!

But... Why did you mount the headlight cover upside down?

Thank you all, I have the running and turn lamp in the bottom hafe, and wanted to keep them amber. Thinking of adding daytime running/marker in the top. Without cutting the lens, anymore.

Also stuck with stock white for headlamp souronds. (IMG:style_emoticons/default/smile.gif)

[Garland]

I ran in to a bit of a problem when starting my build engine, so I went to the "Garage"

LINK:
> Oil filter bulge, like Jiffy Pop, Fresh Engine first start, help! Michigan Build, 2016 Build-Off

[Garland]

I'm Back from the "Garage" engine is running great. 25 minutes at around 2000 rpm. No oil leaks. Now to swap out the drivetrain. She sounded strong, with that cam.

[Garland]

First here is a few pictures of my home powder coating I did a few years ago. used a small oven, and home gun set up.





Been busy. After the oil pressure concern was solved Garage postings

Also a few of engine exterior build up.













I moved the engine on to the trailer, yard trailer.






Out with the old stock 1.7 still running well, after 40+ years, and 5 different cars.



slowly down and away.

[Garland]

Still on its way out.











A few items I had waiting for this it next service.



Here we go….new power, I have used that 1.7 and am used to its power, this should be good.

[Garland]

installed a jumper to fool the fuel pump relay.





Fuel pump and filter. Regulator also set at 2.5psi. First pump I installed failed, so had to route this twice.



Also jumper to the 12 volt plug.



Starter wired up.



Finish up the cables and a few other things Ill be set to go.

[Garland]

First start in car looks good, the oil pressure is 42. And no leaks. 3rd road test WOW oil everywhere.

Restart and oil pours out like a faucet.

Cause, thick washers for the oil cooler to mount were installed between the cooler and the block. By me. Ug. They should be out side the cooler with the lock washer, and nut. In turn the seal won't seal! major oil leak, at 42 psi.

[914forme]

Big day for sure, great job. I lost a Black and Decker Workmate once doing close to the same extraction method. So just be careful, I like the idea though.

[Garland]

Well that took a while. Now I need to decide if I drop the engine to replace those seals or do I try to remove the cooler while the engine is in the car.?