DDK - Die Deutschen Klassiker

Fabulous job!!

Another one saved.

Over the years, I've seen loads of cars being restored and all I can say is WOW!!!!!

That paint looks stunning!

Good luck with the final assembly.

The paint looks exceptional Jonathan

Look forward to the re-fit progress

Quality!

Wow

When can I drop my car in!!!!!

Great job

hi all

just a quick one here, as a better update will follow in a while (I have actually put some bits back on the car , but whilst I was checking over the car when it came back to me over christmas I was reminded of Alan.UK's post about signatures of the painters who did our cars



this image is on my dashtop, sadly only an A and probably a u is visible, but its nice to know anyway.....is this a signature that anyone else has got ??

should we start an index of painters signatures for all the cars on the forum ???

regards

Jp

Its been quiet on the update front so I thought I have better post a few pictures



Car is now as follows

spent ages finishing off finishing touches of painting and then bought a proper waxoil type gun......really worth it, car is completely protected, and so was I and the garage floor.....it gets everywhere

Front suspension on, including discs, new brake shields, new wheel bearings, vapour blasted hubs, new poly bushes throughout



Rear suspension pretty much done, including discs, new brake shields, new wheel bearings, vapour blasted arms and handbrake, new poly bushes throughout




Callipers just sent off to be refurbished today



New brake pipes set made up and fitted
new single piece woven finish ruber pipes to connect reservoir to new master cylinder
Interior has all dials in
Handbrake set up and connected
All wiring loom in place
Rear lights installed
New braided stainless fuel lines all in and fuel pump relocated to front of car


Front trunk area has full wiring loom connected and front heater unit connected



Fuel tank ready to go in
front spoiler on with chrome and rubber trim fitted, that took a long time, lots of trial fitting, which was a nightmare asa the thing was already painted (note do this kind of thing before painting the next time !!) made up some new brackets as my car does not have the 2 battery boxes to bolt the spoiler to, so I have made flattened ends of 13mm coper tubing that bolts to one of the holes off the headlamp bowls



Rear heater flapper units blasted, POR 15 and re-built with new rotating discs,cables and surrounds





Cleaned and polished fuel filter



Striped and repainted then re connected front fuse box





Striped and repainted rear electrical panel



Cleaned windscreen wiper motor



New handbrake cables
New clutch cable



Next things imminent;

A few new electrical connectors to be made, to replace the old worn out wires from the CDI unit
Fit front headlamps and make up new wiring to go to new indicator units
Trim the rear bumper bracket on driver’s side so I can fit my refurbished oil tank


Will go to a local trimmer this weekend to drop off the rear seats which need new corduroy and leather to match the style of the Nuremburg seats I have bought from Mark Waring

Bigger jobs

Need to find someone to repair the external brass oil cooling tubes and remake the threads on the aluminium oil thermostats that were stripped when the flexible oil tubes were taken off (braze in new sections for the tubes as mine are slightly crushed, not a show stopper and perhaps I’m being to fussy but……..)




Last night did the door handles, refitted the chrome door window surrounds and glass and new door felt strips, so now I have 2 locking dors


Did a trial fit of the door sealing rubbers and boy are they tight, can’t really shut the doors properly……

So much of my time has been spent undoing things I already did, like

Door glass, as I overlooked the handles have to go on first
Front suspension because the anti roll bar can’t be fitted when its already in place
Fitting the new fuel lines was a trial as the new rubber with stainless only just (and almost not quite) goes through the existing holes in the transmission tunnel

Pedal assembly was hard work…………lovely to clean and paint and assemble with new bushes but a real nighmare installing.....



So far only scratched a few bits on the car, which is good news…..


Regards

Jonathan

always love to see this level of detail on a rebuid. I know from experience how long it takes in addition to the amount of hours just sat thinking of which jobs need doing etc

Great job

It's really coming on well now, Jonathan (you've done more than I thought in fact) , looking fowards to seeing it again soon .

Fantastic thread - inspiration for all.

Love the detail shots that can be used by many for future reference.

Ian

hi

a bit more as I near the home straight....

all the electrics are in

sound deadening done to floor pans and front bulkheads




fuel system all in with new braided rubber tubes

new copper brake lines

refurbished callipers......and how lovely are they....













rear suspension assembled

front suspension assembled





fuel tank in



oil tank in





I stripped both rear drive shafts so I could replace the zinc plated flanges as they were a bit shabby and the drive shafts are being powder coated this week
Good job I did as when stripped, one was a bit pitted. Generally all the ball bearings were nice and shiny chrome with no pitting, but 1, which was probably original had dull balls and the inner spline of the joint had a gouge in it

I know you can't see these kind of things, but just like handbrake cables and clutch cables, they loked out of place to put the old worn ones back.......

so next stop was the engine, which was fun and games getting onto the engine mount, gearbox had to come off to check the clutch, which is fine. In fact the flywheel is the original on, which helps me believe the mileage of 90,000 is genuine and the clutch plate looks hardly touched

















new release bearing is being done

could hardly believe that the 2 bolts would be enough to fix the spider bracket I bought from MB Engineering, but after 4 days its still holding, although I do put a prop under the fan end…….

Certainly makes for easier handing as I must have spent 2 full days cleaning the exterior, with loads of WD-40, toothbrushes, small scrapers and the best part of bed sheet ripped into dozens of rags….

Nice thing on Saturday was taking the heat exchangers off, which I am glad to say were easy, no problems at all………about time something went easy on the job……

Mind you as I am replacing the exchangers I had no qualms about cutting the old ones up with an angle grinder to get to all the nuts…..



Barry will come over and help me put the engine in and fire it up in a couple of weeks, only then wil I know if the electrics are fine, so only then can the head lining go in and the the rest of the interior

All the trim is sitting in the garage so I can begin to make new panels……

Ordered new foam rear seat bases and door cards from Southbound so fingers crossed for a productive May and June





Tentative end date is some time in July……………………..



regards
Jonathan

Looks fantastic Johnathan!

not long now Jon, Silverstone perhaps?