Catch up - Its a wrap!

As Phil eluded to in the last blog....the posts have been few and far between because every waking hour has been spent on this car. This means coming home from work and going straight to the shed....surfacing briefly for dinner (thanks Janine for being star caterer to everyone who was here) and then going back until 11, 12 or even 1am. As far as the weekends were concerned most were 16 hour days.

Exhausted is an understatement. During that time (god knows how many weeks its been its all a blur now) I have had to take a couple of early nights in as the body just wasn't keeping up but even then it was  still no earlier than 10.30.

Anyway to catch you all up, here are the things that have been going on. This is of course over and above the work that was done in the previous blogs.

The radiator came out as it was leaking.

 

And it was re-cored (the bit in the middle with all the tubes and fins was replaced)

And here it is just before it went back in the car. New fan as well. Believe it or not half a days work just mounting the fan. The fan is mounted on the rear this time as that is about 30% more efficient.

The old trans cooler was replaced....

With a new blingy one that sits under the radiator rather than the old one that sat in front of and all but blocked the radiator.

The old gauges were removed 

The holes filled with steel discs that were welded into place....Thanks Tony!

Then the dash was bogged to make it smooth 

Then it was primed

Then the holes cut for the new gauges

After that  it was painted and the new gauges...pictured below

Were all installed

Lastly here are some before and after pics of the engine bay.

BEFORE

AFTER

BEFORE

AFTER

Man what a job....its been massive and there is absolutely no way on earth I would have been able to do this on my own!

 A huge thanks to Roger Duke who seemed to always be there and helped with everything.

To Bill who also pitched in and helped with many odds and ends that needed to be tied up. Also a good source of knowledge when  you need it. Looks great on the end of a vacuum too!

To Tony for all the TIG welding.

Janine for all the background support and catering.

And of course Phil and Jason for all their work on the wiring.

Obviously these blogs don't cover every detail, but if you want to know job by job what was done on the Pop, here is the task list. Oh and note the one last special job right at the end.....

Flush Cooling System

Remove Radiator and take in for recore

Insert threaded boss in bottom tank of radiator for Rad Fan switch

Replace Radiator Cap

Replace Thermostat

Paint and reinstall alternator bracket

Install new thermostat housing

Install new pressure switch for oil pressure warning light

Install new Trans Cooler

Lower right side exhaust to match left and to provide clearance from fuel tank

Install new Accelerator & Kickdown bracket and return springs

Replace Accelerator pedal

Install Accelerator cable

Install Trans Kickdown Cable

Install new Rocker Covers

Remove and replace brake pads with low carbon versions

Replace harmonic balancer and front pulley

Have alternator polished and reinstall

Modify new rocker cover on drivers side to clear brake booster. Install.

Install new air cleaner

Re do front brake lines

Clamp brake lines at 300mm intervals

Buy and install new front brake flexi hoses

Bleed brakes

Clock starter motor and install

Wire up starter motor

Install Speedo drive

Have radiator bottom outlet modified

Make brackets for radiator to install new Radiator Fan

Fit new radiator top mounts

Reinstall radiator and new hoses, add antifreeze

Make brackets and install Rad Overflow bottle

Wire up auto Elec Fan Switch

Change Oil Filter & Oil

Check level and cut new dipstick to suit

Install new Engine Dipstick

Sand dashboard and prime

Cut holes in dash for gauges and warning lights

Install new gauges

Install Dash warning lights

Remove gauges and warn lights for dashboard paint

Remove gauges and warn lights for dashboard paint

Reinstall gauges and warn lights

Install new Fuel sender unit and repair fuel leak

Top up Trans fluid

Check new Trans dipstick length against old one

Install new Trans Dipstick

Install new shocks

Remount coil under dash

Wire Air Horns and mount motor

Fit Stereo

Redo wiring loom

Reinstall inner guard and drivers guard

Install grill/nose cone

Remount and rewire drivers headlight

Tidy wiring in engine bay and clamp to chassis

Install LED taillights

Re run Fuel line in engine bay

Install Window Winders & Door Handles

Raise front of seats

Adjust seat back to come further forward or raise back of seats

Cover lower steering column with shroud

Install Accent lights

Install new Number plate light Tie up all wires under front guards Align headlights Wire tail lights, fuel tank sender unit, brake lights, Number plate light, eye level brake light, rear stereo speakers and rear indicators Fill radiator Install new fuel filter Install column stalks and shroud Fit new steering wheel Fit radiator overflow hose and overflow bottle Install speedo sender unit Fix battery terminal fitting so it clamps on better Tighten gear knob Calibrate speedo ....and lastly.....put the Beach Hop sticker on. I promised myself that wouldn't go on until everything was done! Here we are ready to go.....its 1 am and I still need to pack my bag....that's okay though we're going to Beach Hop!!!!

Next Blog will be pics of the car being driven and used. Yay!