Project Jigsaw Puzzle - The Golf Car

[ldsbeaker]

Sigh.

I am a black hole for BMWs lately.

 

VIN: 2579059

Manuf date: Nov 10, 1971

Paint: 070 Golf

 

It's got some rust, but it's pretty okay. Guess I'll find out as I do a more in depth inspection. It's already stripped, I just have to put this puzzle back together... Easy, right?

(Ran before they put all the pieces back in the box...)

p.s. That's the engine underneath the blanket behind the car...

 

Would love to have her back together by her Birthday... which also happens to be my "other" birthday.

 

Semper Fidelis!

 

Untitled by ldsbeaker, on Flickr

Edited October 1, 2015 by ldsbeaker

[jmr_1602]

Oorah! Looks like a fun project. Wonder if the make EGA roundels?

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[ldsbeaker]

Day One:

 

Numbers matching, a good start.

 

These fans are so funky looking!

 

 

 

 

I'm unsure if this is good or bad.

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Edited October 6, 2015 by ldsbeaker

[ldsbeaker]

Will start with a cleaning and general sorting of the engine.

 

Upper/Lower gasket set (not HG at this moment), new sensors, water pump, tstat, probably a b35 starter, the alternator is an 80A reman, and a rebuild of the Weber.

 

We'll see how things look after I start taking covers off (cam, timing chain/guides, sprockets, yadda yadda)

 

There is a set of headers that I'm hoping are Stahls in the car...

 

The car ran before the PO decided he wanted to take the engine out to make room for a K20 swap...

He also already clearanced 3/4 of the fenders for fender flares, so I guess I'm getting some IE turbo flares.

 

Local joint quoted $40-55 for a re-surface of the flywheel, no reason not to do it at this point.

Edited October 6, 2015 by ldsbeaker

[ldsbeaker]

Day Two:

 

Started teardown. Got the carbie off, looked under the valve cover, and started taking xx years of gunk off.

I'll have to talk to the PO and see if he did ANY maintenance to the car, it looks like a lot of the sealant type surfaces are prepared pretty well and doing their job.

Hate to tear it apart, but the engine is out, I'm already cleaning, may as well go whole hog (minus bearings and HG) 

I'm really surprised at the utter LACK of wires. There are a few sensors that need wires, and the dizzy w/wires is MIA at the moment... But other than that, it's a positive cable, some cables for the starter and alternator, and that's it! Way to go M10!

 

The cam looks okay, but I haven't turned it over to inspect all of the lobes. No wear detected on first look.

Carb look pretty doggone clean, just needs a rebuild, as the gaskets are all looking pretty crispy.

Found a really terrific rebuild DIY for the Weber DGV 32/36 here:

http://www.mk3supra.org/topic/561-guide-rebuilding-a-weber-3236-dgav-carb

Lots of pics, and a pretty good description of all the pieces. I just hope I can find a decent enough rebuild kit to update the whole carb.

 

Other than that, It looks like I have some vacuum ports to cap in a cleaner fashion. This car may have had an air pump eons ago.

Have to start a shopping list, and maybe today I can take the intake and front covers off.

 

 

 

 

 

Edited October 7, 2015 by ldsbeaker

[ldsbeaker]

Not much time today. Need to put engine at TDC. Also need to bring the big socket for the crank pulley.

Everything looks good so far. Pretty excited to see how the chain guides are...

Edited October 8, 2015 by ldsbeaker

[ldsbeaker]

Taking the crank pulley off took longer to set up than to actually loosen it. I gave the button a quick short squeeze and she broke loose, easy as pie.

It does help to have the right tools... (30mm socket, 18v cordless impact, and a flywheel holding tool.)

Cam sprocket has some pretty damn sharp teeth... The other two look fine. Tensioner rail has NO WEAR whatsoever. Guide is burnt oil color, so will be replaced. Oddly, the HG has a section that goes AROUND the timing chain and between upper/lower covers. Absent. UA, burn him.

I have to take the dizzy mount off, drain oil pan, then pull pan...

Then commence to Field Day.

Edited October 9, 2015 by ldsbeaker

[ldsbeaker]

Started blasting today:

Very nice results.