DDK - Die Deutschen Klassiker

hot66 wrote:you might find the hole for the pin in either the pedal or the shaft has been worn by the bolt .

The split pin through the pedal and shaft was all correct and in good condition. The bolt was through the arm and the fork on the end of the cable. It will need need a new shaft (or a repaired one) in due course as it had worked entirely through the nylon bush (see earlier pic) and the hole in the rotor is slightly worn but it will be good for Wednesday.

ok .. thought someone had bodged the clutch arm pin

RobFrost wrote: Quite a bit of corrosion to deal with, as one should expect.
FInally repainted with mirror finish paint. It won't be as good as the original reflector, but it'll be way better than it was

Just reflecting on your H1 lights post (pun intended) and some things that I have discovered along the way....

I have found the 'soak in a tub' Bilt Hamber Deox-C rust dissolver or the 'paint on / wash off' gel version Deox Gel are both very very very effective first-steps or alternatives to using the phosph-containing rust converter chemicals. May need many applications, but both remove the rust like magic. I personally havent found a rust converter product that keeps rust at bay (under the paint) in the long-term, and I've probably tried almost all of them.

The so-called mirror paints need a lot less coats when applied over black paint /primer than they do when applied directly over grey primer.

Wurth black lacquer paint is an excellent water-proof general purpose paint (over etch primer), good as a base for mirror silver paint, and also excellent for interior satin black parts. It can be sanded flat to remove paint runs and finally orange peel with 3000-grit and T-cut'd to get an amazing looking flawless finish if needed...

Keep up the good work (and pace!)

Frunk looking much tidier with the repainted tank back in. Just a shame I couldn't find time to weld around the battery box on this occasion. Would have been preferable to do that with the tank out but you can't have it all.

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After refitting the pedal assembly and all the fuel hoses in the frunk, I pulled out the dashboard dials in turn and checked all were fully connected.

I doubt the temp gauge works, but the problem appears to be elsewhere.

And the end of the speedo cable can be rotated effortlessly inside its sleeve - also feels like it cam be withdrawn easier than one might expect so I suspect most likely a break in the cable or less likely it's detached the other end.

A look the other end reveals a huge amount of fine metallic-looking grease running down the gearbox. Not sure what to make of that. First guess without cleaning up would be abraded gearbox but it could be some kind of grease.

Will clean it up tomorrow when I get the car off the ramps.

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One of the Headlamp bowls would ideally be replaced due to rust. But the part only seems to be available for model years either side of mine. For Wednesday's visit to Caffeine & Machine air-cooled appreciation society I'm a bit paranoid the H1 lamps could fall out, as they're only held in by a single bolt through a threaded sheet metal tab, in which the thread is slipping.

So I'm holding a nut on the back using the bolt, with a view to tacking the nut in situ.

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I could do with a lightweight portable welder as getting this one out for a 2 minute job and hooking up the large gas bottle is time-consuming.

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Wet rags on the nearby bodywork in the vain hope of protecting the paintwork (fwiw).

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Like an idiot I've gone in with way too much power and managed to weld the nut to the tab, and both the bolt and the grips to the nut.

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After some careful cutting out and re-welding, both nuts are on. It's not pretty but it works so I'm a bit more confident of coming home with as many headlights as I set off with. This is the worst of the bowls, which will need replacing or repairing properly in due course.

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not many of would admit to welding the grips to the headlight bowl but great to see these jobs being tackled

Awesome

Maybe it’s time to buy a new glass for the welding helmet so you can see where you are going!

All us DIY'rs have done something similar!

Gary71 wrote:Awesome

Maybe it’s time to buy a new glass for the welding helmet so you can see where you are going!

My grandad used to say a bad workman blames his tools And I'm definitely a bad workman because I'm blaming the glass.

Fuel hoses refreshed under the car.

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