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 Post subject: Re: at long last... '76 Opel by Isuzu
PostPosted: Tue May 28, 2013 5:49 am 
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Joined: Wed Jul 30, 2008 7:45 am
Posts: 106
Location: australia
wow we didnt get the air pump motor till the early 80's...and no coupes on the aussie market with that motor!!!
good to hear that she runs :D


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 Post subject: Re: at long last... '76 Opel by Isuzu
PostPosted: Tue May 28, 2013 6:12 am 

Joined: Sun Apr 20, 2008 12:37 pm
Posts: 539
Location: Sugarhouse, Utah
as promised:

http://www.youtube.com/watch?v=8l3iucuG ... e=youtu.be

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 Post subject: Re: at long last... '76 Opel by Isuzu
PostPosted: Thu May 30, 2013 12:15 pm 
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Location: Magna, UT
NICE!!! 1 more thing off the checklist.

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 Post subject: Re: at long last... '76 Opel by Isuzu
PostPosted: Thu May 30, 2013 8:47 pm 

Joined: Sun Apr 20, 2008 12:37 pm
Posts: 539
Location: Sugarhouse, Utah
don't worry, there's still plenty more to do!

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 Post subject: Re: at long last... '76 Opel by Isuzu
PostPosted: Fri May 31, 2013 9:15 pm 

Joined: Sun Apr 20, 2008 12:37 pm
Posts: 539
Location: Sugarhouse, Utah
so my carb kit came, but I won't be able to get to it until maybe Sunday. in the meantime, I finished putting the cooling system together. I filled it with just water until I find and fix all the leaks, so I'm not wasting coolant. anyway, I put my pressure tester on it, pumped it up, and the water valve going into the heater core leaks. not horribly, but it does seep. maybe it just dried out over the years and some coolant will help? I doubt it, but it never hurts to hope. couldn't find one on rockauto anyway. good luck finding it. also, the clutch fan is done, too. you can shake it back and forth probably half an inch. I'm thinking of just converting to electric on that. anybody know how hard or expensive it is? the other question about that is, are they low-profile enough to fit in the stock location, or do I have to mount it in front of the radiator? oh, and what about the shroud? leave it off or put it on?

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 Post subject: Re: at long last... '76 Opel by Isuzu
PostPosted: Sun Jun 23, 2013 8:58 pm 

Joined: Sun Apr 20, 2008 12:37 pm
Posts: 539
Location: Sugarhouse, Utah
ok, well I got the carb rebuilt. took me a couple weeks working around all the other crap life throws at you, but I finally got it back on today. I got it to fire up a few times, but not long enough to adjust anything. it wouldn't idle. eventually it just wouldn't start at all anymore. I checked for spark, and it does still have that, so it's gotta be fuel delivery. then I noticed that no matter how long I crank it or pump the pedal, the level in the bowl wasn't really going down, so I'm thinking the carb's just not letting gas into the motor. I checked the electrical plug to the carb, and there's no power, so here's my theory: anti-dieseling solenoid shuts off the fuel when there's no power, right? I figure it's just not opening. now, as far as I can interpret from the diagrams and manuals, that power is going to come from the fuel pump relay. AHA! these cars are kinda known for those going out. of course, the solenoid itself may be bad, too. I think some more testing is in order. I'll let you know what I find out.

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 Post subject: Re: at long last... '76 Opel by Isuzu
PostPosted: Mon Jun 24, 2013 8:54 pm 

Joined: Sun Apr 20, 2008 12:37 pm
Posts: 539
Location: Sugarhouse, Utah
well, I pulled the connector off the fuel pump relay, put a jumper wire in the appropriate place, and it fired right up! I was able to keep it running for probably a good half hour or so adjusting timing, idle speed, and mixture. it actually runs pretty good now, but it does stumble off-idle. maybe there's some adjustment I can do with the accelerator pump. I even ran it through the gears (on stands) to make sure they all worked. so far, so good. but just about the time I was going to shut it off for the night, feeling satisfied about the work I'd done, a coolant hose sprung a leak:

Image

oh, well, I guess it's better to find it in the driveway than out on the road. not surprised, though. those are some old hoses. during this testing, I decided to plug the relay back in, thinking, "I bet it won't run". it did. wtf? so either the relay is just going bad and not dead yet, or there was just a dirty connection there. I think it would probably be safest to grab a spare just in case.

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 Post subject: Re: at long last... '76 Opel by Isuzu
PostPosted: Sat Jul 06, 2013 10:11 pm 

Joined: Sun Apr 20, 2008 12:37 pm
Posts: 539
Location: Sugarhouse, Utah
ok, well, I got a little more done... I decided I'd better get the trunk figured out so I could put up the exhaust and put gas in the tank. so far, the trunk isn't done, but it's getting there. here's what I did:

we remember that it looked like this the last time anyone saw it:
Image


so I made a cardboard template and attacked that spare door, and this is what I cut out:
Image


welded it in (it looks like crap, but as long as it holds...)
Image


then I made another template and hacked the door up some more:
Image


welded that one in too:
Image
that's what's kicking my butt right now, trying to get it all put together. but I think this will end up being temporary until I can find good replacement sheetmetal. right now, I'm just trying to get this thing on the road legally and safely. oh, and I've given myself about a month from now to do it. man, I hope I can... I know it won't be perfect, but as long as it's legal.

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 Post subject: Re: at long last... '76 Opel by Isuzu
PostPosted: Mon Jul 08, 2013 12:11 pm 
JNC Enthusiast
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Joined: Sun Sep 26, 2010 11:46 pm
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Location: Magna, UT
Just make sure the welding you do is quality and you probably wont worry about replacing the sheet metal later.

Good luck and keep it going.

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 Post subject: Re: at long last... '76 Opel by Isuzu
PostPosted: Sat Jul 20, 2013 10:15 pm 

Joined: Sun Apr 20, 2008 12:37 pm
Posts: 539
Location: Sugarhouse, Utah
alright, let's try and get you an update here...
so when we left off, I was patching the trunk together.
Image

got it to something semi-acceptable, and threw some paint on it.
Image

then I sprayed all the rusty stuff with this:
Image
Image

then I went over the underside fairly heavy with this:
Image
Image

when that was done, I put a couple gallons of gas in the tank (my lawnmower had to wait a couple days) to see if it would pump fuel. nope. so out comes the fuel pump.
Image
Image
so I went ahead and ordered one.

in the meantime, I picked this up for $15:
Image

this is what I'm thinking with it:
Image

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 Post subject: Re: at long last... '76 Opel by Isuzu
PostPosted: Sat Jul 20, 2013 10:17 pm 

Joined: Sun Apr 20, 2008 12:37 pm
Posts: 539
Location: Sugarhouse, Utah
so then I decided to try to hang my exhaust:
Image
there I ran into more trouble...
I had an exhaust leak at the flange where it bolts up to the manifold, so I tried to tighten it up.
this was the result:
Image
yup. broke the manifold.
Image

so I had a machine shop weld it back together for me.
Image
I got it put back on, and I took care of the leak, but now the fun part comes. the center pipe that came with the car isn't the right one. it's for a federal car, and this was a california car. they take different exhaust systems. so the mounting isn't in the same place. I get to figure something out for that. in other news, I spent a little time messing around with the lights trying to get everything working, and for now I've got all my lights! horn even works! oh, yeah, the new fuel pump came:
Image

so I put it in.
Image
the jumper wire was just so I could see if there were any leaks before starting the car. it's plugged back in now and working nicely. now I don't have to stand over it feeding gas into the line with a squirt bottle. oh, and don't worry, that hose does have clamps on it now.
so now I have to set up the fan, get the exhaust figured out, and get the glass figured out. plus there's still some other little stuff after that. but at least now you're up to speed.

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 Post subject: Re: at long last... '76 Opel by Isuzu
PostPosted: Sun Jul 21, 2013 10:22 pm 
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 Post subject: Re: at long last... '76 Opel by Isuzu
PostPosted: Mon Jul 22, 2013 10:54 am 
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Location: Magna, UT
Very nice work on reviving her. Seems like your out of the woods now.

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 Post subject: Re: at long last... '76 Opel by Isuzu
PostPosted: Sat Jul 27, 2013 9:34 pm 

Joined: Sun Apr 20, 2008 12:37 pm
Posts: 539
Location: Sugarhouse, Utah
ok, bit of an update...
so I figured I would try to make the old exhaust hangers work on the new system. I was all set to start cutting things apart when I saw that that part just bolts on.
Image

I unbolted it, straightened it out because it looked like it had been hit, and bent it a different direction to support the system.
Image

then I realized I didn't want to weld that piece straight to the pipe, so I cut off the old mounting plate thingy.
Image

found the best place for it, and welded it on the pipe.
Image
the picture makes it look a lot better than it is. the back part of that plate is completely unsupported. the only place it's welded is where you see in the pic.

then I did something that made me feel a little better about the work I'd been doing:
I put on the hood.
Image
it made it look more like an actual car.

I felt so good about it, I decided to clean up its area a little bit. I put away some of my tools, took the car off the stands, and backed it out of the carport so I could sweep up a bit.
Image
it got there under its own power.
Image
so it now supports its own weight, and is mobile. I plan on getting a drive video up soon. WE'RE GETTING THERE!!!! :twisted:

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 Post subject: Re: at long last... '76 Opel by Isuzu
PostPosted: Wed Jul 31, 2013 9:43 pm 

Joined: Sun Apr 20, 2008 12:37 pm
Posts: 539
Location: Sugarhouse, Utah
for your viewing pleasure:
http://www.youtube.com/watch?v=7nzBrCyK ... e=youtu.be

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 Post subject: Re: at long last... '76 Opel by Isuzu
PostPosted: Wed Jul 31, 2013 9:45 pm 

Joined: Sun Apr 20, 2008 12:37 pm
Posts: 539
Location: Sugarhouse, Utah
so I ordered a couple things from Summit the other day, and they showed up today:
Image

there was a mounting kit for the fan, and this, which is an adjustable thermostat/switch thingy to turn it on and off.
Image

you'll have to bear with me from here, as the picture quality gets worse as the sun goes down. I started by mounting the fan, but I had to remove the radiator to do it, because there was not enough room to reach in front.
Image

then I had to figure out a place for the probe. the instruction sheet showed that it shoud be mounted right near the fins, but it actually didn't call for it to be pushed in. so this was my solution:
Image

then I had to figure out how to mount the switch. I decided a handy place would be mounted right to the relay box.
Image

once I had it mounted, I put back the vacuum switching valve that I had to move out of the way. I ran the power wire temporarily to the battery and tested the system.
Image

I adjusted the switch to turn on at what I felt was a reasonable temp (no idea, because the gauge doesn't work), and looked around for a good place to take power from. then it occurred to me: alternator. it's like 6 inches from where I was working anyway.
Image
so I hooked it up there and tested it again. everything seems to be working fine. so now I have a cooling fan.

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 Post subject: Re: at long last... '76 Opel by Isuzu
PostPosted: Mon Aug 05, 2013 9:10 pm 

Joined: Sun Apr 20, 2008 12:37 pm
Posts: 539
Location: Sugarhouse, Utah
well, today I went to the dmv and got a 15 day permit for the car so it can legally be driven for testing, repairs, etc. I drove it to and from work today. feels good knowing that I brought it back to life. I did that. it's something I can be proud of.

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 Post subject: Re: at long last... '76 Opel by Isuzu
PostPosted: Tue Aug 06, 2013 5:28 pm 

Joined: Sun Apr 20, 2008 12:37 pm
Posts: 539
Location: Sugarhouse, Utah
well, after driving it a couple days, I have a bad rear main seal. it's pretty bad. I am really frustrated right now. I didn't want to have to pull the trans this soon.

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 Post subject: Re: at long last... '76 Opel by Isuzu
PostPosted: Sun Aug 11, 2013 7:24 am 

Joined: Sun Apr 20, 2008 12:37 pm
Posts: 539
Location: Sugarhouse, Utah
ok, here's the pics so far:
first, I took a picture at work next to a co-worker's car just because it was looking particularly small that day...
Image
that's a brand new Nissan Versa. they're not particularly huge, are they?

alright, so...
I got the car back up on the stands in its familiar position
Image

pulled the exhaust
Image

disconnected the driveshaft
Image

went inside the car and removed the shifter
Image
don't worry, I stuffed a rag in the hole.

disconnected the speedo cable
Image
(see, there's the rag)

went up top and unplugged the electrical connector
Image

went back underneath and disconnected the clutch cable
Image

unbolted the starter
Image

wiggled the trans out
Image

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 Post subject: Re: at long last... '76 Opel by Isuzu
PostPosted: Sun Aug 11, 2013 7:25 am 

Joined: Sun Apr 20, 2008 12:37 pm
Posts: 539
Location: Sugarhouse, Utah
then I removed the clutch
Image

and the flywheel
Image

to find that the leak wasn't really coming from the seal... it was the oil pan gasket.
Image

so then I undid the motor mounts and lifted the engine a bit
Image

drained the oil so it wouldn't sploosh me in the face
Image

and dropped the pan
Image

here's the gasket
Image

and here's my opinion of it
Image
so that's where it sits right now, and the meet is this evening. wish me luck, I'm going in!

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