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classicJackets HalfDork
7/7/17 2:29 p.m.

Well, dangit photobucket. Luckily, You can see more recent images still, thanks to Google Photos. I suppose I'll have to go back and re-link many of these..

Skervey HalfDork
7/7/17 2:54 p.m.

Im in the same boat I lost all of my build photos...

mck1117 Reader
8/1/17 4:51 p.m.

You wouldn't happen to still have the Merkur shell, specifically the steering rack, would you?

classicJackets HalfDork
12/7/17 6:17 p.m.

Contrary to Popular belief, this build thread isn't over yet. I have another week at home to work on this before being busy for a while, then needing to move it up to Michigan to start in the real world!

The last day or two I've been trying to work out what my transmission crossmember and mount will look like, around the cold and rain here. 

This picture shows what i have to work with: 2nd from the top is the stock transmission mount. Height and location of the mounting bolts for the center aren't right.

The top/cardboard is what the horizontal piece would need to look like now to clear the humps in the transmission. 


Now, the lower two pieces is where it gets interesting. I bought the bottom mount for $5 thinking it would be all I needed - today, I ran into the top piece. I had it tucked away somewhere, and now I'm considering the merits of trying to use it - problem is I can't remember where it came from to research what it would look like in place!

I was able to find the following picture on Google for comparison.



This person just used both. The advantage to using the more "flat" mount is that it could tuck up in the frame of the truck, the disadvantage is I think it could end up being harder to build a mount for, and I really don't know how it looked in original form.  I'll snap some pictures under the truck tomorrow when it's light out for better comparison.



classicJackets HalfDork
12/8/17 8:12 p.m.

Okay, so as it turns out - the mystery piece above is an exhaust hanger mount. Sweet. Not a good transmission mount!

I dug through some more scrap bin today and found these mounts - I think they came with the parts Merkur a while back. One of these pieces was free-floating, but the other had to be cut off a pipe it was welded on to (in the background)


The slots were cut in the pieces already, which is why I really wanted to use them. Here you can see they overlapped and needed to be trimmed down.


Next step is always CAD model, here they're already trimmed to size.



Marked the steel to size, and cut those back tabs off:


Had to go out and buy the hardware, but then mocked them up. The fit worked out pretty well even before welding.



Welded and cleaned up. This side will face the ground normally.


Here's the mounting side.


I decided I might as well use the exhaust hanger, and cut off the tab on the driver's side because it would be unusable, thanks to the parking brake cable.


SO in the next few days, if the snow/sleet stops, I can get back on the ground and try to start making the rest of the crossmember to weld to this mount.





Robbie PowerDork
12/8/17 8:57 p.m.

Yes! I'm so excited to see this build back in action. Moving to MI huh? Maybe I'll even be able to see this thing in person one day!

classicJackets HalfDork
12/9/17 10:48 a.m.

Proof that we got snow in Georgia!

classicJackets HalfDork
12/9/17 11:24 p.m.

Didn't get a ton today, and didn't take many pictures while I was working. I did, though, get the transmission positioned where it needed to be in the frame, as it was more skewed before. I did have to cut the trans tunnel some, but the floor is rusty enough in enough places that I don't feel too bad. It's all for the cause!



It's a tight fit but a little better now. Hopefully I can take all pieces of this a little further in the next few days and get this portion wrapped up!

Edit: I've been working backwards now, trying to fill in some of the pages of missing pictures. I think I've covered the last 2 or 3 pages, and will keep working back!

classicJackets HalfDork
2/19/18 8:46 p.m.

I'm back... And I've moved to Michigan! The house I'm renting has a 2-car (a little oversized) garage. I already just about filled it up. Plenty of organizing to come.  And talking to the property manager about having more electricity added, the 2 outlets in there aren't quite enough if you ask me. I finally bought an LED light to hang yesterday.


I changed my rear main seal this weekend, and I'm expecting a new flywheel, clutch kit, and clutch slave cylinder to come in this week. Once those are in, I'm hoping to be able to get the full block dropped in and begin addressing the concerns there.


In the meantime, I've been looking at the seats again. Because I know earlier pictures disappeared, here's a refresher. Out of a VW Corrado, great bolstering.


I am anticipating needing to make new mounts, both to weld on to the seat and to weld to the car, once the floors are cleaned up/patched. 


For seat mounting panels, what gauge steel would you be looking at using? Here's a picture of the CAD template, on the back side and bottom of the seat. Definitely gussets would be involved, but I'm thinking weld on the triangular portion, and drill two holes to bolt through to captive nuts in the floor. Would 16 gauge be thick enough? 14?


Dusterbd13 MegaDork
2/19/18 8:58 p.m.

Id go 1/8, but im captain overkill 

Crackers Dork
2/19/18 9:17 p.m.

Dude, I'm gonna be looking hard for a set of those seats. 

As far as mounts, I'd probably also go with 1/8" with how you're planning to attach them. 

If you can box it, 16ga would work. 

Saron81 New Reader
2/20/18 6:39 a.m.

Cool project!

I have almost the exact same truck... mines a green 73 with the stock engine and automatic. I was originally going to do a 2.3 turbo swap in it as well, but decided it was too nice to swap (until it breaks at least.) Might go 302 power at that point though. ;)

I’ll be watching!

BlueInGreen44 SuperDork
2/21/18 3:44 p.m.

Nice seats.

Welcome to Michigan! Some guys here are planning to hang out soon. Check out the   GRM get together thread if you haven’t already.

classicJackets HalfDork
2/25/18 5:42 p.m.

Nice to know there's another Courier on the forum!

BiG, thanks for the heads up - I'll plan to be there.

I didn't get much done this weekend, but I popped out today for long enough to get the freeze plug at the back of the block replaced, and the pilot bearing replaced. I used the "bread trick" on the pilot bearing, and honestly it worked really well. The new one is in and good to go. 

This week I'm hoping to get the old block pulled, a few of the remaining pieces of brackets drilled off/removed, and the real engine block dressed with clutch/flywheel and dropped in place. We'll see whether that happens or not!


classicJackets HalfDork
3/10/18 9:19 p.m.

Been a busier few weeks than the post history here would suggest. I've been working on getting the garage organized, getting the right parts here, and chipping away still a little bit at a time!

The garage looks better now..


After the engine gets put in, I'll have to find somewhere to hide the hoist - but there's almost enough space for a 2nd car in there now!


In that picture, you can see my new, too cheap for my own good, corner notcher. I got it looking like this


Cleaned it up a little bit and ended up with something that looks almost respectable! Just need to do  the handle next.

On the car itself, I did get the timing belt and tensioner changed on the ingoing engine. I changed the freeze plug on the back of the block as well. I have the clutch and flywheel here, so once I get the dummy block pulled and the engine bay cleaned up a little better I'l be ready to drop everything in!





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