Spending time in the frunk
 

I was looking forward to this step because it involves a number of fun and simple jobs. I also took the time to make it a little better than originally planned. Here is how the to-do list went down:

1. Gas struts, even old ones, are too much for the fiberglass hood. How am I going to hold this thing up so I can work on it? Sherwood? :cool:

2. Install a headlight relay kit and test it (holy smokes, all the old relays and steering column stuff works!)

http://forums.pelicanparts.com/uploa...1431039147.jpg

3. These rubber bushings in the strut tops have got to go. Monoballs please…

4. Simple strut bar in black is more like it. Chuck!

5. Fitting a carpet kit I bought 7 years ago. Wanted the snaps, so I marked it all and sent it to Bob and his crew at Appbiz and they installed the snaps for me gratis (MUCH appreciated Bob).

http://forums.pelicanparts.com/uploa...1431039236.jpg

6. Really want a good light as I will be opening the hood to gas this baby up. I couldn’t resist a modern touch based on bang for the buck/lumens. Seriously bright (and lightweight) solution. It runs off a factory contact switch installed on the RHS hinge.

http://forums.pelicanparts.com/uploa...1431039464.jpg

http://forums.pelicanparts.com/uploa...1431039825.jpg

That is about 10 watts total. Kinda cool. Here are a couple shots of it all finished up:

http://forums.pelicanparts.com/uploa...1431039641.jpg

http://forums.pelicanparts.com/uploa...1431039664.jpg

Progress!

Nice LED light strip! Did you get those from superbrightleds.com? Is it just mounted with adhesive tape?

When I got the Stratton duck tail, I lost the mounting point for the engine compartment light. This might be a great solution for both ends of the car.

LED's came from Amazon:

Amazon.com: LE Lampux 12V Flexible LED Strip Lights, LED Tape, Warm White, 300 Units 3528 LEDs, Non-waterproof, Light Strips, Pack of 16.4ft/5m: Home Improvement

Will be interesting to see how the supplied adhesive holds up. I am optimistic being it is in the frunk and touching fiberglass (and the car is white). Without more information I would not trust it in the engine bay yet due to the heat loading.

Body Electrical
 

Wow, I thought I was over the hump on electrical work once the EFI was complete. WRONG! All 4 corners needed help, either due to age or custom needs. Here are the front corners all buttoned up:

http://forums.pelicanparts.com/uploa...1434692049.jpg

http://forums.pelicanparts.com/uploa...1434692059.jpg

http://forums.pelicanparts.com/uploa...1434692069.jpg

I ran extra wires to power the city lights in the H4’s. Going to try that first and forego installing the R parking lights for a cleaner look up front.
All that work creates the following cool result (yes, the headlights are on):

http://forums.pelicanparts.com/uploa...1434692099.jpg

That would be R turnsignals from TRE, 55/100 bulbs powered thru the JWest relay kit, and all the electrons flowing thru factory column stalks, a ’68 headlight switch, and a ’71 ignition switch. Phew!

The back end received the same treatment. Nice to FINALLY see these installed (will do more fitting once the rear bumper is on for good):

http://forums.pelicanparts.com/uploa...1434692151.jpg

Here is a mess that needed to go away:

http://forums.pelicanparts.com/uploa...1434692193.jpg

A few hours later you get this pile of trash…

http://forums.pelicanparts.com/uploa...1434692224.jpg

… and something much more manageable:

http://forums.pelicanparts.com/uploa...1434692253.jpg

Body Electrical – continued
 

Needed to rebuild the wiring for the interior lighting, too. Runs to the lights were good, but the door contact switches got the treatment and now work (simple pleasures):

http://forums.pelicanparts.com/uploa...1434692430.jpg

Extra goodies in the cabin required new custom harnesses for both sides. Many hours of work later I now have nice working wires running up into the dash and front trunk areas (for ECU functions, future hidden stereo system, and yes… seat heaters :p):

http://forums.pelicanparts.com/uploa...1434692450.jpg

Even with all the add-ons this area still looks pretty good:

http://forums.pelicanparts.com/uploa...1434692491.jpg

New wiring follows the factory stuff for the most part, so it doesn’t really stand out. Square relays are for the headlights, red relay is for the fuel pump (did that a long time ago) but is now signaled by the EFI ECU. All needed fuses are in except for the windshield wiper circuit (probably should check that :rolleyes:). Only electrical not hooked up will get completed when I build up the dash (final gauges and switches). Just one more easy harness to build for the license plate lights (once the decklid goes on). Dangerously close to starting the interior work... :D

looks great doug...!!
carry on "dangerously" as you say as you are doing just fine...)))

Nice build man!

Just a friendly heads-up; The gas cap you are using looks to be a ventilated cap. Not sure you want this in an "under the hood" application. BLAU makes a non-ventilated version as well.

Cheers!

Johan

Hmmm... that explains a few things. Thanks for that! I'll have to bug Dave B. about it next time we chat...

Somewhere along the way I did get a wheel done...
 

I just love 15 step/20 hour jobs :rolleyes:. I am pleased with the results and will get the other 3 to match this one:

http://forums.pelicanparts.com/uploa...1436044476.jpg

http://forums.pelicanparts.com/uploa...1436044488.jpg

Like usual, the final shot of matte clear (which turned out to be not so matte nor completely clear) darkened everything it touched. Up to that stage the primer gray was just what I was after, but the final result is growing on me. Tough to see, but the aluminum lip is top coated with clear gloss, so technically there are 3 different top coats.

Speaking of jobs that can take a while…
 

I decided to tackle the headliner install myself. I will work it in parallel with fitting the H4’s to the fiberglass fenders… because the only thing more fun that doing 1 tedious job at a time is doing 2 at a time, right? Did all the right research (hopefully) and here we go:

1. Interior lights get their wool surrounds
2. Foam in the rear window top vent
3. Sound deadener panels on the roof
4. Fabric/foam headliner material on the roof
5. All the screw holes I will need have screws in them so they are easy to find later
6. Painted the bows with gloss paint before slipping them in the headliner
7. Pre-ran some wires for a third brake light inside the driver side C-pillar

http://forums.pelicanparts.com/uploa...1436045878.jpg

http://forums.pelicanparts.com/uploa...1436045894.jpg

http://forums.pelicanparts.com/uploa...1436045914.jpg

Binder clips and glue are waiting in the wings. Wish me luck! SmileWavy

You're a brave and talented man. Great eye. What color is the headliner? I'll def be emulating some of your touches. Thx mark

Thanks Mark. The vinyl headliner its from Autos International and is ivory. excellent quality. I have had it out of the bag and hanging up for at least a couple of months now ahead of the install. if I end up with any wrinkles in the end they will only be my fault...

10'-11". A 911 can ride all the way up to the stops and not hit the ceiling and I can walk under it AOK. I am 6'-1" tall. I think a 10' ceiling would be cutting it close, but if you are shorter it could work. It is really nice to be able to comfortably stand up under the car. If you miss it by a couple inches it is awkward and I believe you would find yourself wanting to sit down more often than not. Certainly would still work, just not quite as accommodating. Hope that helps...

Binder Clips for sale...
 

Translation... the headliner is in! Tough to take good pictures, but here are some:

http://forums.pelicanparts.com/uploa...1440792249.jpg

http://forums.pelicanparts.com/uploa...1440792261.jpg

http://forums.pelicanparts.com/uploa...1440792275.jpg

I am very pleased with the results all things considered. Hats off to the pros that can do this job in 4-6 hours. I must give the bulk of the credit to my lovely wife. It was a fun project to work on together... I know what it is supposed to look like and she can make it happen. It only took about 1.5 hours to align and tension it and feel like we could start trimming and gluing. Then we bit off each tricky spot one at a time. Big help was to pre-tension the next work area prior to stopping for the day. Few days of sitting and the new area was all set for wrinkle free work. Great material to work with.

Been loading the doors with parts and sizing up the dash work. Once we wrap the A and B pillars it will bw time to go after some glass.

Thanks,

Nice job on the headliner!

+1 on the headliner. Been there....it's tedious and time consuming, but worth the effort.

subscribed

Al, I believe it was one of your threads that gave me that first little push to try doing it myself. I would not hesitate to do it again...

Fun couple of weekends...
 

Well, with the headliner in the interior work can really take off. Started with the rear window:

http://forums.pelicanparts.com/uploa...1442205799.jpg

http://forums.pelicanparts.com/uploa...1442205809.jpg

Wow... finally put some glass back in the car :rolleyes:.

Rear window in means I can put the decklid together. Restored grill and lights went on quick since I did all the real work before paint:

http://forums.pelicanparts.com/uploa...1442205982.jpg

http://forums.pelicanparts.com/uploa...1442205998.jpg

Hinges all fit fine, just need to finish the wire harness for the lights. Hopefully my next post will have a shot of it flipped over laying on the rear window.

After a looooooong wait, the day(s) finally arrived to get the dash put together:

http://forums.pelicanparts.com/uploa...1442206188.jpg

http://forums.pelicanparts.com/uploa...1442206199.jpg

:D:D:D

More Glass (Vent Windows)
 

Man it takes a long time to install these from scratch! Lots of parts and a strong desire to not mess up the new paint or the fresh headliner make for slow going (think 4-5 hours per side). Starting with the bright work and the black trim that covers up the headliner edges:

http://forums.pelicanparts.com/uploa...1446173784.jpg

http://forums.pelicanparts.com/uploa...1446173794.jpg

http://forums.pelicanparts.com/uploa...1446173805.jpg

Then one more black piece of vinyl to hide the paint color on the B pillar:

http://forums.pelicanparts.com/uploa...1446173918.jpg

After all that "fun" installing a new outer seal on the window frame, it gets fit loose/rough so the inside latch can go on:

http://forums.pelicanparts.com/uploa...1446174123.jpg

http://forums.pelicanparts.com/uploa...1446174140.jpg

I skipped some details here (spacers under the trim, terostat, getting to the fastener holes thru fresh upholstery, etc.) but I have a better set of pictures of the LHS window going in if anyone is interested...

Windshield Install
 

But had to deal with my dash top first. The original pressboard dash piece I had was in decent shape but shrank too much with age to fit well, so I decided to make a new one out of fiberglass. Too bad I had already wrapped the pressboard version in new vinyl :rolleyes:. So, rough cut to shape:

http://forums.pelicanparts.com/uploa...1446174929.jpg

Lots of back and forth fitting and trimming, then finally drilled the holes and fit it with the plastic pins:

http://forums.pelicanparts.com/uploa...1446175022.jpg

4 hours to get to that stage but very good results. I was able to get the vinyl off the pressboard and onto the fiberglass with the help of all those binder clips I seem to have laying around now. It was like headliner work all over again:

http://forums.pelicanparts.com/uploa...1446175236.jpg

And installed:

http://forums.pelicanparts.com/uploa...1446175263.jpg

http://forums.pelicanparts.com/uploa...1446175281.jpg

The windshield was all set to go with a factory seal and new trim, so after a couple false starts my son and I got it installed for good without too much drama.

http://forums.pelicanparts.com/uploa...1446175505.jpg

Sweeeet!!!

Great work and great job narrating. Thx for the show.

Where did you source the sheet of fiberglass? How thick was it?

Made the f/g sheet myself as I have the resources readily available to do so :cool:.

It is about 1/8" thick (12 plies)...

Looking really good Doug. You two did a great job on the headliner.

Forgot the decklid pics...
 

Rear decklid is on for real now. Wired in and lights work. I am using a factory latch/release setup for "security" and a clean look:

http://forums.pelicanparts.com/uploa...1446394308.jpg

http://forums.pelicanparts.com/uploa...1446394635.jpg

Now I just need to get that darn rear bumper back on so I can final fit the rear tail light housings to complete the back end...

But before I do that...
 

I am continuing with the interior work. I am not a big fan of the '68 break away interior rear view mirror, so early on I decided to go with a '65-'67 chrome mirror, which would require me to make an adapter plate. All good, except I forgot to do that before the headliner install! I am a little bummed about this as I missed the opportunity to hide it, but it is not too visible when all is said and done and I took the time to finish it off nicely:

http://forums.pelicanparts.com/uploa...1446395209.jpg

http://forums.pelicanparts.com/uploa...1446395224.jpg

http://forums.pelicanparts.com/uploa...1446395242.jpg

http://forums.pelicanparts.com/uploa...1446395257.jpg

That last shot is hard fought. You would think that installing the sun visors would be quick and easy, but anything that has me working with the fresh headliner is kind of tedious. But that should be the last time, so I am grateful for no slip ups!

If the exposed mirror adapter ends up bugging me, I didn't do anything to the headliner that would preclude me from going back to the '68 style mirror. Guess it can just be a conversation piece for those that look real close...

One more thing to take care of in the interior, then it will be time for carpet install.

My early mirror has an annoying vibration while driving. Anyone have any ideas how to stop this?

R_Builder
Really enjoying following this project. I can be a bit OCD and perseverate details, so in regards to your headliner/rear view adapter conundrum I think it adds to the purpose-driven aesthetic of the R. Of course, not my car but just wanted to let you know that another guy out there who sweats similar issues thinks it fits the look.

To further my point, the engineers could have likely found a way in which to hide the rear deck lid hinges whilst still allowing the lid to fully open. In the end, they sit atop the lid...and, come to think of it, have a similar look to your rear view adapter.

Only one joint that could be loose... and I suspect the glass has to be out to work with it :(. I have not crossed that bridge before (and hope I will not have to).

Thanks jac1976. Time will tell, but it serves the purpose for now and I can move on to the next steps!

Soundproofed the rear seat area
 

Carpeting process is moving along nicely (but no pics to share yet). First step was to put a little soundproofing in the rear seat/parcel shelf area. This is the 1/8” thick, adhesive-backed stuff from Aircraft Spruce. Not too much to it but to do it:

http://forums.pelicanparts.com/uploa...1450544810.jpg

http://forums.pelicanparts.com/uploa...1450544828.jpg

This is all it will get. Not planning any science projects here. I guess I can always go back and add stuff to the floors pretty easily if need be, but that would be a different product for sure.

Weird to see it all get covered up after so long....

It is not the glass. The entire mirror vibrates from the roof where it is mounted. I have tried tightening the screws. If you put your finger on it, it will stop.

My 1970 MG Midget (I know, not the same type of engineering - but with the same wobble) made every headlight in the rear-view mirror look like the headlights were making circles. I made a rubber gasket the shape of the mirror mounting to absorb the vibration, and the world was stabilized. Try it, it just takes some material with the ability to have some cushioning.

Well… the carpet is in!
 

See:

http://forums.pelicanparts.com/uploa...1453697822.jpg

Oh wait, you probably don’t really want to see all the scraps :p! How ‘bout this instead?

http://forums.pelicanparts.com/uploa...1453697886.jpg

http://forums.pelicanparts.com/uploa...1453697897.jpg

http://forums.pelicanparts.com/uploa...1453697909.jpg

http://forums.pelicanparts.com/uploa...1453697920.jpg

I used 3M spray 90 just about everywhere, but the floormats are just sitting in place for now. Just like the headliner, I must give most of credit to the wife for helping to make the carpet install successful. We make a good team on these types of jobs...

As you can see, there is more progress than just carpet since it all needed to be worked together. Roll bar went in finally (bought it from TRE a loooong time ago), everything around the pedals is closed out, the engine ECU is mounted for good, shifter and p-brake are in (with heater wire and handle throttle hooked up), seat brackets installed, and… sills/thresholds closed out:

http://forums.pelicanparts.com/uploa...1453697961.jpg

I will probably spend a little more time fussing with the sills and lower door jamb areas to get the vinyl wraps and carpet strips looking better, but they are good for now.

Guess it is about time for some chairs, eh? If you look close, you can see that I have also started in on the last big assembly step… the doors. Lots of parts involved there, with fit checks, more upholstery work, seals galore, and fiddling with the door frames. More on all that stuff next time.

Take care,

Long overdue update...
 

As always, time flies.. but slow and steady progress this year. Looking back in my pictures, it looks like I moved back to the rear to rehang the bumper for good:

http://forums.pelicanparts.com/uploa...1473553067.jpg

Then back up to the front to truly get the headlight buckets ready for the H4's (lots of trimming for a good fit, lower brackets, drains, safety zip-ties, etc.):

http://forums.pelicanparts.com/uploa...1473553129.jpg

http://forums.pelicanparts.com/uploa...1473553143.jpg

Then it was back to the doors. Finally got to hang these gems and install the roll up windows:

http://forums.pelicanparts.com/uploa...1473553278.jpg

http://forums.pelicanparts.com/uploa...1473553326.jpg

Like I have mentioned before, there is a lot of time spent getting all the door stuff working right and all the seals in place. But in the end, you finally get to put these on :D:

http://forums.pelicanparts.com/uploa...1473553463.jpg

The outer trim and window swiper finish off the outside, and the car is finally all tight:

http://forums.pelicanparts.com/uploa...1473553753.jpg

Took a little while to get up the nerve to drill into the door frames for the updated wind blocks, but all turned out just fine:

http://forums.pelicanparts.com/uploa...1473553854.jpg

The proverbial light(s) at the end of the tunnel:

http://forums.pelicanparts.com/uploa...1473553925.jpg

Doug, I always enjoy your updates. Keep up the good work.

What is this?

Tim

Everything is so well done..... Really love the fuel lines, what kind are they?

awesome! thanks for sharing!

Thanks Tim!

"wind blocks" from our host's catalog:

http://forums.pelicanparts.com/uploa...1473819741.jpg

They close up the gaps between the door shell sheetmetal and the window frames at the front and rear. Just something from the later cars that will work on the earlier cars...