<VV> 65 Corsa project update

Macdonald David dmacd_us@yahoo.com
Mon, 12 Jul 2004 09:49:40 -0700 (PDT)


This weekend was Corsa weekend for me.

I took the car out the barn it was stored in and set
to work on things other than the engine for the first
time.

Project one, code named Tar Baby, was removal of the
(already cracked) windshield. The windshield was held
in by the standard glue tape stuff but after 30+ years
I could simply push on the window form the inside and
it came right out. Someone had filled in gap between
the body and the windshield with a black tar like
substance. I think it was roofing tar as it seemed to
have some fibers of some type in it. I spent at over 3
hours on Saturday digging this stuff out a couple
inches at a time. I quit with the job unfinished as
the mosquitoes began to feast on me around 7 pm.  

I started again on Sunday and work proceeded much
faster as the sun was warming the tar and it was much
softer. I used a wire wheel on the drill to get what
was left off. This was quick work and the wheel
quickly removed the tar and just as quickly deposited
it on my face. The wheel warmed it up as it took it
off so that it stuck really well wherever it landed.
Wife and kids were really amused, the dog was scared.
I had to use mineral spirits to get the stuff off.

Discoveries:
Found brazing in all four corners of the windshield
area where metal has been replaced. I guess this car
is not as rust free as I thought it was. If Ralph
Nader wrote a book about how this part of a Corvair
was badly designed, I!&d recommend it.


2) Project two was an examination of the brakes. All
the drums are in good shape although they have a fair
bit of rust from so many years of non-use. None of the
wheel cylinders are leaking. I!&m going to remove all
the drums and have them lightly turned to remove the
rust, rebuild all the cylinders and replace all the
hoses.

3) Project three was a determination of why there is
so much slop in the steering. Turns out that steering
box is badly in need of a rebuild and the idler arm is
shot. Tie rods and ball joints seem tight and OK. So
project three proceeded to the remove the steering box
phase.

I spent a long time trying to get the pitman arm nut
removed. I don!&t like to use and impact wrench on
steering boxes because I think it might be bad for
them. I started with the five foot pipe on the breaker
bar method using just about enough force to flex the
breaker bar but not break it. Please don!&t ask how I
know where the breaking point occurs. This method did
not work. 

I then applied some heat to the nut, which set the box
on fire because it covered with steering gear oil and
PB blaster soaked undercoating. Soon there was a
Flaming River of oil and undercoating coming off the
pitman arm. If I ever start a company making steering
boxes I think I!&ll call it Flaming River : This
method did not work.
I gave up and just let it have it with the impact
wrench. After several minutes of forward and reverse
impact wrench activity, the corners of the nut were
beginning to smear away and I was ready to resort to
cutting the nut off. But I gave it one last session
and it finally moved.

I carefully followed the instructions in the shop
manual, and was offended to find that I had to cut a 2
inch hole in the inner fender well to get the steering
box out. I will tear the box down later this week and
see if I!&ve pounded dents into the inner workings of
the box.

I took some pictures of the car and I!&ll post links
as soon as I figure out how to get the pictures shrunk
down to a reasonable resolution.

Cheers

David
!&65 Canadian 4 Carb Corsa Coupe
(That has not moved under it!&s own power since May
!&74)
Acton, MA



		
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