my low budget dream car build

[PorterF]

Woohooo!

Congratulations!

[jpnovak]

Most Excellent. Did you let it run and break in the cams?

[chrisbalich]

Originally Posted by jpnovak

Most Excellent. Did you let it run and break in the cams?

Not yet. The alternator isn't charging, so I shut it down after less than a minute.


Speaking of the alternator not charging...
I added a ground wire from the alternator body to the engine as I was told a painted fan housing can cause a no-charge situation. Still no dice.
I verified the two grounds inside the fan shroud (to engine case) are good.
I verified the charging [idiot] light works and its circuit is good.

So I'm left with either the voltage regulator or the whole alternator.

Does anyone have any idea on how to verify one or the other?
I get no charge light on the dash with the key on, and no volts when the car runs.

Thanks in advance!


EDIT:

Just ordered a new Valeo. I should have it Tuesday. I'll be able to break in the cams Tuesday night or Wednesday.

[jpnovak]

First clue: No charge light with key on. Without this bulb working there will be no excitation signal to the alternator to charge.

Try replacing the bulb or checking your wiring to that bulb. should be on a blue wire.

Is your car internal or external regulator?

[chrisbalich]

Originally Posted by jpnovak

First clue: No charge light with key on. Without this bulb working there will be no excitation signal to the alternator to charge.

Try replacing the bulb or checking your wiring to that bulb. should be on a blue wire.

Is your car internal or external regulator?

I verified the bulb and the wiring, both separately and together.
First, I unplugged the blue wire from the bulb and ran a wire from the second bulb terminal to ground. Key on, bulb lit up.
Second, I plugged the blue wire back in to the bulb and grounded the blue wire at the alternator (no alternator in place). Key on, bulb lit up.
So my wiring and bulb are good. After adding the additional ground wire from alt body to engine case, I concluded that the alternator itself has failed. I am unsure if it's the voltage regulator or the internal wiring and there are no electrical shops open during the apocalypse, so for $300 I just ordered a new Valeo unit.

I will either dive deeper into my current failed unit later or just have it rebuilt and shelve it for future use.

My car has an internal regulator. I am unsure if it came that way as it's a 79. But that's how it was when I received it and I've replaced the whole engine loom anyway, so that's how it's set up now.

Thanks!
CB

[breakerbar]

I spent the better part of the weekend catching up on the last two years of your p-car life and I had to let you know the heap is looking awesome! It has been great to ride shotgun on your journey.

The pic of the laptop on the dash was nice, but here is a better view for your inspiration. It's gettin' close, man, real close!

[Jonny042]

Congrats!!!!

Glad you got it going, that's awesome.

[MFX]

Congrats mate. The first start up is both exhilarating and terrifying. I am petrified of starting mine

[chrisbalich]

Originally Posted by breakerbar

I spent the better part of the weekend catching up on the last two years of your p-car life and I had to let you know the heap is looking awesome! It has been great to ride shotgun on your journey.

The pic of the laptop on the dash was nice, but here is a better view for your inspiration. It's gettin' close, man, real close!

Thank you!
I'm super close. Today is supposed to be new alternator day. That means I'll run-in the cams tonight.

Originally Posted by Jonny042

Congrats!!!!

Glad you got it going, that's awesome.

Thank you. You're not far behind me.

Originally Posted by MFX

Congrats mate. The first start up is both exhilarating and terrifying. I am petrified of starting mine

Thanks!
For real. I hate first starts. It took me almost a whole day to even turn the key on my first big engine build several years ago. This one was just as terrifying. You can see in the video where I stuff my hands in my pockets. Apparently that's something I do when I'm uncomfortable. I was freaking out on the inside. It took me a moment to get my life together enough to remember to check for oil pressure and leaks and listen for errant noises. I was so shocked that it fired up without much drama.

I'm certain yours will go super smoothly. You're a pro!

[chrisbalich]

A day late and a dollar richer*, it's time for my WEEKEND UPDATE. (* I found a dollar on the ground yesterday. I am not rich.)

By now, we all know that I was able to start the hog over the weekend. And we know I have a failed alternator. We may also know that the new alternator is set to be delivered today. So that means that barring a Red Dawn-esque situation, I'll be running in cams tonight.

In the interim, I've been staying busy checking off other items on my list in an effort to make my bucket a little less of a bucket...

I know you guys expect buffoonery and madness when I make updates, but I'm going to try to let you down easy this time. In an effort to ward off the entropy that follows me everywhere, I installed...seatbelts. *gasp* No pics as they're just seatbelts. But I'd nearly forgotten about them. The webbing needs replaced (40 years of wear), but something is better than nothing. This will at least keep me legal, if not a tiny bit safer.

The seatbelts came about as I'd started fitting the interior carpeting and panels. I want you to look back into the far recesses of your memories and recall when I redid the door panels some year and a half ago. (Was it two years?) They're quite tidy and I really like them. But they did not look good next to the OE vinyl clad rear side panels. Something had to change.


That's right. The vinyl. With all the allure of cheese left on the kitchen counter for two weeks, it was deigned unworthy of a build such as mine. Seriously, it's got a gooey sort of feel to it. IDKWTF happened to this stuff, but it's wicked gross. Absolutely vile to handle.

Being a jack-of-many-trades, I set about replacing that rancid vinyl with the [dare I say perfect] tweed I'd redone the door panels in. The learning curve here is quiet steep and I reckon I'll be redoing the passenger side at some point. But there is a specific order of operations that ought to be adhered to if you intend to get the best possible result. I was in the ballpark for the first panel, but the second one came out much better.

Sticking to my methodology of using what I have about, I used a combination of spray adhesive (3M super 90), contact cement, and staples to hold the new coverings to the old panels. Whilst the adhesives were adhering, I reinforced their mighty grip like this.


With the first panel [somewhat acceptably] sorted, I started on the second. While the adhesives where drying on #2, I installed #1.


You can see quite clearly in this picture why I'm not super stoked with how this panel came out. It's loose around the bottom and has some weird dimples where I'd used glue on the front and then the clamps clamped a trifle too tight. All of these issues were resolved on the second panel. It's a masterpiece by comparison.


I also got the backseat heel panel of carpet installed. I needed to get it in to get the ECU mounted, but kinda forgot about not yet having an appropriate grommet/seal for the harness passing through the bulkhead. A quick glance through my stash of parts, odds, and ends, and this is what I came up with.


With panel #2 done, I realized it would be imprudent to install it without first installing the quarter window. With ever increasingly furious/sore fingers, I dug out the box, installed the seal, installed the [GDMFingIH8ThisThing] trim, soaped up a rope, and shoved the window home.


Next time:
fit a new alternator
run in cams
retrim the parcel self cover
install the rear window
install the driver's side side panel
install the parcel shelf cover
start working on the front kick panel carpets
actively seek out a sponsor for a new windscreen seal. (I'm more than a little concerned if I drive with a rear window, but no front window, the rear will pop out.)

[Flojo]

like that matte/satin grey paint.
but these red fuchs always distract me.
the need an appropriate color.

[chrisbalich]

Originally Posted by Flojo

like that matte/satin grey paint.
but these red fuchs always distract me.
the need an appropriate color.

The red fuchs are temporary. (I hate them in red)
I have some CCW Race Classics that need refurbished and fresh tires and they're going on. I was actually sizing up tires for the CCWs yesterday. Working on a game plan but wheels are less important than running right. So all in due course.

[Ginger77]

Get some matte black Plastidip for the time being.

[chrisbalich]

Today's plan was to sync the ITBs.
Sounds simple, doesn't it?

Act I: Ad Lib
Well, I read and re-read Clay's ITB syncing guide from his ITB/EFI build thread.
Then I gathered the necessary tools and went out to the garage.

I opened up the garage door and as I belly'd up to the engine bay, I remembered how much fun it is to have my open headers burn my legs while I stand [precariously] between them and attend to the engine.

So I did some really janky isht.


These are resonators from a late-model Audi. I got them to use the resonators and bends to build an exhaust from. But it occurred to me that I could [sorta] bolt them to my headers and get most of the exhaust (and a fair portion of the heat) behind me instead of directed into me. It looked ridiculous. But it tamed the rowdiness of the exhaust a lot more than expected and it saved me from being lit on fire by my own car.

Act II: Drama in the engine bay
Bespoke exhaust working like a charm, it was time to sync ye olde ITBs.
So I removed the rain hats, removed the IAT sensor from the rain hat, plugged it back in, and set it to the side-ish.
Per the instructions, I disconnected all the relay rods and then fired up the hog.
Started with #1...so far, so good.
#6...not bad.
#2...NBD.
#5...killing it. Feeling good.
#4...You'd think I knew what I was doing at this point.
#3...WTF. F me in the A. WTH? How can this be? #trynottopanic

The syncrometer didn't even register on #3. Like no air moving at all. My first thought was, "Oh no. The rings didn't seat. I have to tear this whole GD thing back apart. Do I just sell it? I don't have the budget, let alone the stomach to do this all again..."

Syncrometer in place, I blip the throttle.
Syncrometer zings up like you'd expect. :/ #confusion "does it have compression?"

I decide I'll try to seat the rings. So I move Kelly's car out of the drive. Back the 911 out of the garage. (oh yeah. First drive) And take it up and down my road...twice...in first gear with heavy engine braking. Interesting looks from the neighbors. Grey car, red wheels, no windscreen front or rear, exhaust all kaddewampus out the back like a pokemon, idiot behind the [not bolted down at all] steering wheel.

Back to the garage.
Syncrometer on #3.
Second verse, same as the first. No air moving.
Shut it down. Phone a friend.
I'm ready to do compression test, he wants to know about the idle/throttle linkage.
Many texts and a picture or two exchanged.
He asks for a moment to think.
While Joe thinks, I peer into #3 and compare it to #2 & #1. It looks canted way further clockwise than the other two.
I push left bank throttle to WOT.
#1 & #2 are 6-12.
#3 is 7-1.
:/ Something is amiss.
So still holding bank 1 at WOT, I adjust the screw to roughly align #3 to the other two.
I start the car. It immediately idles different than before. #hope
Syncrometer on #3.
Readings!
I compare to #2 & #1...close, but not quite. I adjust all on bank 1 until they match.
Miraculously they match bank 2.
A quick throttle blip and it revs like a sport bike.
I shut it down.
I text Joe. All is well. My near panic attack was not for more than poorly aligned ITB butterflies. Good grief.
I sit on the wall, texting Joe and Kelly comes out.
"Hey, I'm going to get dinner. You ok?"
"I am now. I'll go with if you've an open seat."
I close the garage door and get in Kelly's car.

End Scene.

That whole isht was more stressful than the pre-first-start-jitters. I need a drink.
...of water.

[obscene]

I think Kelly is my favorite character so far

[chrisbalich]

Originally Posted by obscene

I think Kelly is my favorite character so far

She's my favorite as well.
But she and Joe have both been integral to getting the car this far.

[Gabe.]

Hahaha, that is amazing that you drove around your neighborhood with those Audi downpipes mounted up. Looks hilarious.

Planning to put up any vids of that snappy throttle anytime soon? Can't wait to hear that with my own ears.

[75 911s]

Haha oh man love the drama. And yes the Red Fuchs must DIE! :-D

[chrisbalich]

Originally Posted by Gabe.

Hahaha, that is amazing that you drove around your neighborhood with those Audi downpipes mounted up. Looks hilarious.

Planning to put up any vids of that snappy throttle anytime soon? Can't wait to hear that with my own ears.

My neighbors all think (know?) I'm a maniac/pirate anyway.
I'll see what I can do. I need to break down and buy one of those little 100 knuckle tripod things to hold my phone instead of haphazardly leaning it against stuff.

Originally Posted by 75 911s

Haha oh man love the drama. And yes the Red Fuchs must DIE! :-D

I think I'm |.......| this close to a reality show on TNT or E!...

I have a scheme brewing to get the CCWs refurbed and installed sooner than later. Another week or three of the dreaded reds and they're gone for good.

[baloo]

Just came across this post, so a lot of catching up.
I'm impressed you have persisted this far.
When I started reading your initial posts from back in 2018, my mind was already composing a response ("Been there, done that, and understand too painfully the amount of work and money you will have to spend -- on a project that is most likely to end up sitting around due to being overcome by life events, or by other more interesting cars...")
BUT, I see you have persisted beyond most normal humans!

Congrats!