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Discussion Starter #101 (Edited)
Such a beautifully simple engine! I'm used to seeing the complicated modern timing chains with way too many pulleys.

And I’m used to seeing a simpler untensioned short chain with some 6” push rods. There is a second chain to the oil pump that I won’t be touching right now. Gotta find an end to the “project creep”.


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Come on, you should know that there is no end!
 

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E21, E83
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Discussion Starter #104 (Edited)
Swapped chains and guides today. This required removing the cam sprocket by bending the lock tabs and removing the 10mm bolts.
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With the sprocket removed the guide holding the chain could be turned out of the way to clear the exposed portion of the cylinder head gasket.
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The old guides/tensioner rail were in great shape, as was the cam sprocket. I***8217;d never guess 240k miles!
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New tensioner barrel on the left, original on the right. While I could blow through the old one in only one direction, as I should, the check ball was not freely rattling around. I***8217;m sure I could have cleaned it up without issue, but the new one was so cheap, I opted to replace.
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Ready for the covers.
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I had planned to install the covers today, but two of the lower cover bolts also secure the alternator bracket, which had a broken bolt in it (steel and aluminum like to become one), so I had to extract it.

Tried vice grips first, easiest option first. No luck.
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Then on to what I assumed I***8217;d need to use: my welder. Welded a 7/16-14 nut to the stud shaft.
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Unfortunately with the wrench it further sheered the stud at its weak end. No biggie, onto a 1/2-13 nut so I could get more weld material and better penetration. Got the sucker red hot... yes it***8217;s glowing.
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Did the ***8220;2 steps forward 1 step back***8221; routine with the wrench, and the stud came out without issue.
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I didn***8217;t like the threads, especially after the heat and corrosion, so I then cleaned them up with a 1.25 metric tap. I of course used ***8220;Tap Magic***8221; as a lubricant.
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To finish off I painted the crank pulley (grey) and the alternator arm (Avignon blue metallic, which seems to be pretty close to the car's Saphirblau paint).

Off to sea for the weekend (I***8217;m pissed I wasn***8217;t on the ship for Isiais!) but I hope to get the covers back on next week. Stay tuned.


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Much better!
 

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D'oh, You Kids!
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Yup! Use non-copper-bearing anti-sieze, coat both the threads and the bolt shanks.
 

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E21, E83
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Discussion Starter #109 (Edited)
Yup! Use non-copper-bearing anti-sieze, coat both the threads and the bolt shanks.

I ONLY use Ford hi temp nickel antiseize on everything.

The Ford stuff is the best I’ve ever found, FYI.

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That ignition module/power stage looks WAY too clean!


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Discussion Starter #115
Replace the radiator support today. Here’s what I was working with. Also decided to fill the screw holes in the fender and reinforce the frame.

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Cut the old support out.
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Clamped and tacked a piece of 2” angle iron in. It’ll definitely be stronger than it was, even new!
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Welded two 1/8” plates to reinforce the rotted frame.
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Discussion Starter #116
Welded the angle in, and then welded in some 1” pieces of 3/8” round stock because the radiator mounts were too rotted at the bottom.

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Plugged all the holes in the fender.
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I still gotta clean it all up but it’s 95*, my shop has no AC and after 3 hours hovering above 3k* metal, I called it quits. At least now I’m almost ready to drop in the rad, pump and hoses!


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Those fenders will look really nice all cleaned up with the holes filled in! I can't stand cluttered engine bays.
 
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E21, E83
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Discussion Starter #118
On the frame plates, in hindsight I should’ve used wider plates. Laying the bead resulted in numerous blow-throughs, which of course then led to having to add material to fill in the holes, which of course then detracts from aesthetics.

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Discussion Starter #119
I got attacked by some beers last night and didn’t feel like doing anything today. So, I did some menial tasks.

Installed the alternator, and remembered I had some wiring to replace.
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Wire brushed yesterday’s metal work, then shot it with primer, and paint on the rad support and frame repair. I still need to clean up the inner fenders, but needed to get primer on the bare metal to prevent flash rust in this humidity.
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Coated each cam lobe with moly grease and poured a little oil over the top end before installing the valve cover.
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Set the radiator in place to see how it looks and confirm that the mounts were correctly placed.
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With the car up in the air, used my impact to zip the lugs out and pull the wheel, so I can heave some room to work to install the clutch master and slave this week hopefully. The brakes don’t look terrible, but my immediate plans for the car have changed so I’m going to end up going through all of it anyway. Once running, I think the car might become my daily driver, to sip that go-juice!
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Replaced all the heater hoses. Also grew weary of seeing the t-stat assembly on the floor, so assembled the new one. Parts box is shrinking!
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E21, E83
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Discussion Starter #120
Made the last post sitting on the stool staring at the car, and decided to zip the rear wheel off too just to see what I got. Not terrible at all, I’ve definitely seen worse. The hard brake lines are in great shape!

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