More room in the Shop | Learning Wrenching Rebuilding

A automotive is much more compact when it’s all put collectively.  Elements take up quite a lot of house.  That is the costly half. I’m making an attempt my greatest to restrict that however typically you don’t have a alternative. Different instances, you do and nonetheless determine monetary burden. I imply, reuse all of the previous (completely high quality) crappy parts on a freshly painted automotive? I can’t convey myself to do it. Nevertheless, I can reel myself time to time within the identify of expediency and frugality(an actual phrase?).

I’ve been fairly busy for the reason that final replace. The large effort being an entire new brake system entrance to rear, gas plumbing, re-plating {hardware}, pedal field meeting, and discovering components seven(!) years after I took them off the automotive. I can and have been doing a couple of issues in parallel and make some modest progress nevertheless it’s onerous to finish one activity fully. The issue is, most of those duties are serial. I can’t bend the brand new traces with out the grasp cylinder in. I cant put the grasp cylinder in till I get my powder coated components again, can’t meeting these till I re-plate the {hardware} and on and on. However what I can do is figure on one thing else! So this sport of spherical robin continues till I save sufficient to get the components I have to do the factor that lets me do the opposite issues.

Brakes: I purchased stainless traces from the Their costs had been affordable they usually shipped them shortly. I additionally purchased stainless gas line from them as properly. The brake fittings I bought from amazon,

I bought this line bender

and this flaring device



Then I 3D printed some mould components.


All in all they turned out fairly properly. I could make extra so should you want a set, $25 shipped however it’ll take a couple of days to get all of them molded.   


I purchased new flex brake hose from ebay that claimed to be NOS brake hose, it was low cost and appears the half.

With the brake traces bent up and all in place I turned to the gas traces. I made a decision to run the road underneath the motive force facet which is the place I feel the return for the Tii initially went. It turned up on the pedal field and used flex hose to the filter king mounted above it. I purchased an inexpensive gas pump from RockAuto and mounted it in entrance of the gas tank underneath the automotive. To do that I bent up just a little bracket and welded on a nut that the pump “P” bracket can screw to. It got here out okay.


Please ignore the cobb webs.



I had a E21 clutch grasp cylinder from some time again that I assumed was a direct alternative for the 2002. Seems it’s not. With a 2002 clutch grasp cylinder costing about $180 I figured I’ll attempt to make a budget $40 E21 one work.

20221224_130342.thumb.jpg.d319009b1207083881460bcb8ffd1914.jpg        20221224_134246.thumb.jpg.3353e4f6e3256b363e0ecc013a5de8dd.jpg


I turned down a cylinder out of 6061 on the lathe and had some 3/8” 6061 flanges reduce from SendCutSend. This took two iterations as initially I used a 1/8″ flange and deliberate to make use of a nut behind it however did not have sufficient room.  So I needed to bump up flange thickness and thread it. I made an offset fixture for the lathe to show down the middle of the flange whereas leaving bosses on the ends. I feel it got here out fairly properly.


I tapped the flanges for M8 x 1.25 Heli-Coils then welded all of it up. The weldment match up fairly properly and whereas technically didn’t save me a lot cash, I do have materials to make 5 extra assemblies. So, let me know if you’d like one!


So, brakes achieved, clutch achieved, gas achieved. Subsequent massive hurdle is get the engine in. With the assistance of some buddies we bought the engine off the stand, mounted to the subframe, match up the trans, and slid the entire meeting underneath the nostril of the automotive.


We incrementally lowered the automotive till it was time to lift the subframe. It took about 2 hours to get the engine set.


Engine in! Now wiring. It is a massive activity.

First, I molded firewall grommets utilizing the ID from this thread for the wiring harnesses. On the passenger facet, I made some plugs for the air con holes.

I began unwrapping the entire electrical tape and changing it with Tessa Tape. I bought a pack of it from amazon and it’s a lot nicer to work with. I additionally purchased new electrical contacts and a crimp device. It took me a short while to trace down these components so right here’s the record of what I discovered works properly for changing contacts.


These are the components from Digi-key:


1   42098-2_tmb.jpg A100614CT-ND
CONN QC TAB 14-18AWG 0.25 CRIMP        $0.17 ea.     
2   60620-1_tmb.JPG A1420-ND
CONN PIN 14-20AWG CRIMP TIN     $.0.25 ea.  
3   60619-1_tmb.JPG A1421-ND
CONN SOCKET 14-20AWG CRIMP TIN     $0.23 ea.  
4   60701-1_tmb.JPG A27925CT-ND
CONN QC TAB 10-14AWG 0.25 CRIMP     $0.27 .ea


5 42238-2_tmb.JPG A36375-ND
  CONN QC RCPT 14-18AWG 0.25          $0.22 ea.   
5 180384-2_tmb.jpg 180384-2-ND
  CONN QC RCPT 10-12AWG 0.25          $0.33 ea.






I additionally bought these warmth shrink connectors from amazon for the connections that aren’t in a housing.

Qibaok 320 PCS Warmth Shrink Spade Connectors


To correctly crimp all of those onto  the wires I bought this crimper set.  It really works fairly properly particularly for the value level.

HKS Ratcheting Crimping Device Set 9 PCS

I purchased further wire to splice in the place wanted and run new wires.  I additionally bought battery cable.  I bought all of it from  Their costs had been far more affordable than the vast majority of different distributors I discovered.  They usually shipped in a short time.


I blasted components at house then had a beneficiant coworker who bought them trying good all powder coated.  I additionally prototyped the gauge pod.  I’ll most likely do yet another (or two) iteration to higher marry the sprint bump for the the gauge cluster.











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