I mentioned in my last post in this series that I broke a motor mount boss stud off, well, it turned out to be a pretty involved process to get it repaired. When I mentioned the problem to ‘expert’ friends they all said ‘Oh, those studs never want to come out’ well, I broke it off installing a new one, not removing the old, bent stripped stud. I’ve broken studs off before on other rebuilds and was ready with the usual arsenal of tricks.
First I tried simply grabbing the remaining piece with Vise-grips, no good. Then I drilled it out and used an easy out seen below, I couldn’t get a grip on it so I welded a nut to the easy out, the easy out broke at the weld. I got a bigger easy out and tried to turn it, it was resistant despite a lot of force. I heated the boss and tried again, this time the corner of the boss cracked.
Here I am at the first attempt, the easy out wasn’t so easy and even with a nut welded to the end it wouldn’t turn.
Step three was a bigger easy out with heat. All I managed to do was crack the corner of the boss.
Once I cracked the boss I decided it was time to get expert assistance. I Dremeled out as much of the stud as I could, disassembled a bunch of the engine and took it in the trunk of the Berlina to an appointment I made with Glenn to weld up the crack. He Dremeled the rest of the stud out, welded up the crack, installed a Helicoil, accepted a check for $50 (labor and a thermostat cover) and helped me get it back in the trunk. Expert assistance is under rated!
Here I am back at the shop getting ready to unload the engine. Fortunately there is an engine hoist in the shop so this is a one man job. Berlina was on the bump stops when I drove with the engine in the trunk. In a perfect world I would give it new springs and shocks as I suspect they are worn out, but that would cut in to my Sprint/SS budget.
Here I am, back where I was a week ago, getting ready to install the engine mount. Note the finishing machine cut on the edge of the block when they cut the engine mount boss face smooth.
I had installed the flywheel without aligning the timing marks so I used the disassembly required by the transport as an excuse to remedy this so I took it back off and aligned it. When reinstalling the clutch I noticed some alignment marks between the clutch and flywheel which I aligned. As can be seen here, I need to paint the starter.
This is the 750/101 1300 breather. Mine was cracked so I dropped it off and Dennis at NRG welded up the crack and smoothed it out. $20
What is left to do you ask? Well, my Lucas distributor was deemed unfixable by Jaan so I need a new disributor, hopefully a Bosch unit will surface (anyone?). The exhaust side engine mount still needs to be installed as do the rest of the oil pan bolts. I need to get a big hose clamp to try and compress the Giubo and test fit it before I make it an under car operation. I still need to paint the starter and alternator bracket. Oh, and I need to decide if I am going to install a mechanical fuel pump and cap it off as a back up in case the Facet dies again when I am out in the wilds on a rally. I am hoping to begin the install late this week.