nonextant

Aaacchh! Nothing worse than snapping a bolt, making a job much more involved. I hate it when that happens.

Haven't done much today, too busy at work. I did pull the headlight relay again and reflow the solder a 2nd time. This time I added a bit of solder to some of the lighter points and the headlights are working reliably now.

I'm also fairly confident the leak is coming from the sunroof and maybe a little from the passenger door seal. Will pick up some weedeater line tomorrow and snake the drains.

pjg

Managed to get a hole drilled in the bolt with the right angle dremel, cobalt bits would not put a dent in it, needed to use a titanium bit. Next step is easyout after letting it soak for a while in liquid wrench. Never had much luck with the easy out seems its the only option from this angle. That gouge on the side was my feeble attemp at trying to get it to move with a cold chisel.

F451

I'm not sure what the options are, but I would not use an Easy Out.

They are notorious for snapping off and then you have that stuck in there they are a bear to drill out since they are so hard (and brittle - which is why they snap in the first place).

pjg

I agree with you, easy outs are not the best choice.

Speedtoys

Im not familiar with the bolts on this model...how far down would he have to drill out the shank to get the cover free from it?

Speedtoys

Absolutely!

pjg

Did manage to get the damaged bolt out by drilling the hole to the tap size, then retap the hole. Easy outs would not work I tried both types spiral and fluted.

Mrmerlin

for a ground that will work

kary4th

My $960 car and I are jealous.

backnblack

That car is sweet for 800.00 I could use one of those.

nonextant

Well, the latest on the car, for those interested:

While on convalescent leave for my surgery;
1. I pulled and thoroughly cleaned the CE Panel and the grounds to eliminate any potential gremlins(resoldering all relays resulted in headlights working consistantly).
2. I was able to get the driver's seat fully functional by rewiring some of the leads to the motor.
3. I also took off the PS pump belt.
4. Attempted to repair instrument cluster a couple of times... used hot glue to replace middle tab on the housing, and resoldered and cleaned connections. Kicking myself as everything but the fuel gauge and odometer was working after the 1st time.
5. Replaced bolts securing lock security plate, eliminating rattle from the driver's side door.
6. Threw my Harmon Traffic Pro II radio (unwired as of yet) so I wouldn't have to stare at the gaping hole in the center console.
7. Cleaned door contacts and interior lights are now working.

Currently issues:
1 Passenger seat and window inop.
2 intermittent groaning from the air pump.
3 Massive leak from a PS high pressure hose.
4 Instrument cluster is in a sad state. I have tried refurbishing it a few times, with no result.
Temp and Fuel guage are inaccurate and peg when parking lights are turned on.
Speedometer works intermittently and will not register above 40MPH
Gauge lighting does not work on the cluster, center console lighting is fine.
Odometer is missing some teeth.
5 Steering wheel horn ring tab is missing and I need to replace the upper steering shaft bushing.
6 There is a slight surge when under light throttle (maintaining speed) it's not noticeable at idle or hard accel.
7 Sunroof leaks, but I can only push in about 2 inches into the drain on the passenger side... need to try to clear from the bottom.
8 Need to replace fuel lines for peace of mind (does anyone make a kit for this, or at least have a definitive listing of parts needed for a 1982 US car?)
9 Rear wiper "pops" out of linkage when 3/4 of the way across hatch
10 Hood and Hatch shocks shot.
11 Need to clean out heater box.. slight fan growling during turns and bumps.
12 Need to check out HVAC system, everything only seems to work at full heat regardless of temp setting
13 Door speakers are all AWOL
14 Drivers sunvisor shaft snapped at "elbow"
15 Drivers seat "crushed down" on outside seat bottom.. hard to explain, seat controls lean all the way over onto the handbrake
16 Headliner, passenger side center console cover and o2 sensor counter cover warped due to water leak
17 Spare tire cover and pump are missing in action
18 I think the stereo and speakers were stolen as there is an entire loom cut off where the stereo was wired.


I figure I'll wait for my tax refund and order all parts at one time. I'm hoping to have the car repaired so I can drive it to Georgia when I attend the Senior Leader Course in March.

One more question... My car came with two 15" square or so leather "envelopes" (a lot like the sunroof sleeve on a 944) which contain to oddly shaped pieces of carpet. Does anyone know what these are for?

Skrilla01

Looks like steal,good luck with it

blown 87

If you ever find one for four hundred, hold out for a eight hundred dollar one, I have wanted to burn mine a couple of times.

Yours looks great for a 800 dollar car.

Hilton

1 - is probably the switches. Pull the passenger seat out before opening up the switch, and have a tub underneath it when you open the switches to catch the 4 ball bearings in each! Window switch is more easily got-at and fixed.
2 - cut the air pump belt and leave it for now as it doesn't do much
3 - replace the PS line - can get them rebuilt cheaply, and they leak onto stuff that makes the fluid catch fire e.g. manifold. ATF is very flammable
5 - the tab is part of the horn ring, a cheap part
8 - fuel line kit from Roger of 928srus.com aka ROG100 here on rennlist.
10 - new shocks are cheap, and I was amazed at how strong new hatch shocks are!