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1979 Brat Dual Carb EA81 Swap


LouKoff
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Just waiting on parts for the engine to be reassembled. Expect some engine pics in about 3 weeks when my pistons are supposed to get here.

 

In the meantime I've been working on the body to try to get it as close to ready for paint as I can before I get the engine ready to go. I've got a lot of body work and metal forming to do to fix all the dents and rust on the body, fenders and doors.

 

I cleaned up floor underneath the cab and go it and the transmission tunnel undercoated.

 

27247550061_6dd67606f6.jpgUndercoated by Luke Hoffman, on Flickr

 

26710408424_fddb1024d7.jpgTrans tunnel undercoated by Luke Hoffman, on Flickr

 

Body work pics

 

26710326034_954d10c044.jpgRemoved windshield by Luke Hoffman, on Flickr

 

27317727535_20cd77d0a7.jpgPassenger side body working by Luke Hoffman, on Flickr

 

27220421922_9bbed8685d.jpgDrivers side body working by Luke Hoffman, on Flickr

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  • 2 weeks later...

Working on tackling the exterior rust and other random stuff. Getting anxious to get it painted and driving so I've been working on it a lot.

Here are some pictures of the progress, I've been drilling out spot welds and  cutting out the bad and shaping new pieces to weld in, cleaning up the inside and spot welds with a grinder, flap disk and wire brushes, and doing any little pieces that need to be replace in area inside the panel, then coating the inside with a few coats of cold galvanizing compound. Then I take the piece I cut and make a rough outline/template to cut a new place of flat sheet metal to shape a piece to replace the panel the was cut out using a sandbag sheet metal break hammer and dolly and a small stump. Once I'm satisfied with the shape I trim the piece  to size and work on little tweaking with the panels and final planishing with the hammer and dolly then coat the backside of the piece with the cold galvanizing compound.

Lots of part have been arriving. I have the bearings new water pump and I think I have all the gaskets I need for the engine and carbs, except two gaskets I have to cut out of gasket material for the carburetors base gaskets because I cant find any single ones online and don't feel like buying two more carb rebuild kits to get two gaskets. Waiting on pistons to start assembling the block. Both carburetors have been thoroughly cleaned, reassembled and ready to go back on the manifold once I figure out the carb base gaskets. I made an egr delete plate for the manifold too.

Got some new tires for the peugeot alloys, they're 185/70r14 Nexen CP661s and they look pretty good, especially for $40 a tire. 

I cleaned up the block, removed the studs, and had the cylinder bores honed. Some of the studs were pretty rusty and pitted or bent so I will be using the best ones from the ea71 and ea81, looking at the studs it looked like both the engines had already gotten some new studs.

I've also been working on cleaning up and painting miscellaneous pieces from the engine and engine bay that were rusty or tarnished looking.

 

27478500236_1cedd66dd5.jpgPassenger Rocker pre cut by Luke Hoffman, on Flickr

 

27478508426_04fa9eefbf.jpgpassenger arc by Luke Hoffman, on Flickr

 

27478513736_c3ce907d3d.jpgDrivers rocker pre cut by Luke Hoffman, on Flickr

 

27478519756_4241be6f2f.jpgDrivers Rear Pre-cut by Luke Hoffman, on Flickr

 

27236468530_87628136cb.jpgDrivers rear post cut by Luke Hoffman, on Flickr

 

27236470840_6937acc0c5.jpgPassenger Rocker by Luke Hoffman, on Flickr

 

27512881685_fbcdc7906a.jpgPassenger arch coated by Luke Hoffman, on Flickr

 

27512886005_e591e3aa11.jpgPassenger Rear by Luke Hoffman, on Flickr

 

27512889715_fceba8ec6a.jpgPassengerer Rocker formed by Luke Hoffman, on Flickr

 

27512894535_f4d1b1c94e.jpgDriver Rocker by Luke Hoffman, on Flickr

 

27236487180_450ee9d13b.jpgDrivers Rear by Luke Hoffman, on Flickr

 

27236492220_69e87d1f7d.jpgResult of Wet mouse nests by Luke Hoffman, on Flickr

 

27236499220_ede2af0731.jpgpassenger rocker by Luke Hoffman, on Flickr

 

27478554566_45c7c47464.jpgCoated by Luke Hoffman, on Flickr

 

27478559686_a0dc379480.jpgD Rear by Luke Hoffman, on Flickr

 

27513396775_e1bfb830e1.jpgFresh Rubber by Luke Hoffman, on Flickr

 

27513419365_db8766cfbf.jpgBlock sitting pretty by Luke Hoffman, on Flickr

 

26905569813_45d6af822a.jpgManifold almost ready to go back together by Luke Hoffman, on Flickr

 

27414640062_6413fb46b2.jpgMissing gasket by Luke Hoffman, on Flickr

 

27414641742_d5a4fefc23.jpgCarbs looking good by Luke Hoffman, on Flickr

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Been doing a lot of random stuff trying to tackle little things so they don't hold me up later. Here are some pictures of some of the patch panels welded in.

I will clean up the welds more later when I'm getting the car ready for primer and doing body work. Painted lots of engine parts and the driveshaft. Next up is the radiator and continuing to work on the rust and welding in more "new" panels.

 

27582585351_debfa80588.jpgpassenger arch welded by Luke Hoffman, on Flickr

 

27656558675_c6d0f20c26.jpgpassenger rocker welded on by Luke Hoffman, on Flickr

 

27556181772_4db19ace0b.jpgPassenger side almost done by Luke Hoffman, on Flickr

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Only made it out to the cabin for two days the past two weeks so not much progress, but I did work on trying to finish up my custom moped made with fire extinguisher tanks I found in the garbage. While not working on the brat I painted the frame, sewed up a seat, and started putting the thing back together, ported and rebuilt the moped engine. But I will be going up for a long weekend for the 4th and should be able to get a lot of work done! 

 

Here are some pictures of the body work progress.

 

27651687570_74180e1cf3.jpgDriver Fender Welded by Luke Hoffman, on Flickr

 

27828761772_169ecfe215.jpgFender Repair by Luke Hoffman, on Flickr

 

27651690290_351a7b4421.jpgDriver Rocker Welded by Luke Hoffman, on Flickr

 

27853240271_42a5d29bc2.jpgDrivers Rear Rocker by Luke Hoffman, on Flickr

 

I also got 4 of these in the mail.   :lol:

 

27895705546_54e07c834c.jpgPiston by Luke Hoffman, on Flickr

 

27895709156_165726cec8.jpgpiston by Luke Hoffman, on Flickr

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Little update of the rust repair I got done yesterday.

 

27927959332_d762d4fbaf.jpgDriver Rear Inner by Luke Hoffman, on Flickr

 

27959626281_4ba4890da3.jpgDriver Rear Inner Finished by Luke Hoffman, on Flickr

 

28030609995_3bcbd7cf76.jpgDriver Rear Ready for Welding by Luke Hoffman, on Flickr

 

27750195640_613c44b1d4.jpgDriver Rear Welded by Luke Hoffman, on Flickr

 

27416698533_e2e5118287.jpgDriver Rear Finished by Luke Hoffman, on Flickr

 

27416423204_be929a1da0.jpgPassenger Fender Top 1 by Luke Hoffman, on Flickr

 

27928089662_df0f41feb2.jpgPassenger Fender Top 2 by Luke Hoffman, on Flickr

 

27995679406_96199a36a4.jpgPassenger Fender Top 3 by Luke Hoffman, on Flickr

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Todays Progress

 

Got the Passenger Rear Corner finished.

 

28049524125_4585a97b55.jpgPassenger Rear Arch 1 by Luke Hoffman, on Flickr

 

28015200726_be0205aa8d.jpgPassenger Rear Arch 2 by Luke Hoffman, on Flickr

 

27947492892_a2a08732a6.jpgPassenger Arch Welded by Luke Hoffman, on Flickr

 

28049701955_a8b0e82ee0.jpgPassenger Rear Corner 1 by Luke Hoffman, on Flickr

 

27947430212_2d29eeb793.jpgPassenger Rear Corner 2 by Luke Hoffman, on Flickr

 

Started to work on the Drivers side rear corner as well. Found more rust after cutting so that set me back a bit, but I have all the peices formed just need to trim and weld.

 

27972241561_9e344f57a8.jpgDriver Rear Arch Cut by Luke Hoffman, on Flickr

 

27768903660_3d0c488215.jpgDriver Rear Arch Coated by Luke Hoffman, on Flickr

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Finished up the rust repair on the drivers side rear corner today. Welded in new for the inner skin of the fender, cut the rocker open, cleaned out the mouse nest and dirt the was inside, coated all the inside paneling with cold galvanizing compound, then welded everything up. This side didn't turn out quite as clean as the other fender but it'll clean up nicely with some filler. Next up for repair is fender and doors, but I got a lead on a brat at a scrapyard so hopefully I can run out there and snag some rust free fenders, and a dent free door. Not going to be at the cabin for a few weeks so I'm going to bring those fenders back home with me to work on in case the scrap yard brat is no good. Also in the mean time I will be working on reassembling the engine, went to the auto store and picked up all the gasket sealant, and assembly lube I need to reassemble the engine and I also picked up some gasket material to make the missing carb base gaskets I need.

 

Here are some pictures of the work I did today on the drivers side rear corner.

 

27970221782_101e04e8e0.jpgDriver Rear inner Welded by Luke Hoffman, on Flickr

 

27458950983_423ff30875.jpgDriver Rear Inner Coated by Luke Hoffman, on Flickr

 

27995853661_e37ca27724.jpgDriver Rear Outer Welded by Luke Hoffman, on Flickr

 

27792413990_7a941dfcdf.jpgDriver Rear Rocker Cut by Luke Hoffman, on Flickr

 

28038968646_b450f13faa.jpgDriver Rear Arch 1 by Luke Hoffman, on Flickr

 

27458476333_eca82b6181.jpgDriver Rear Arch 2 by Luke Hoffman, on Flickr

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Went to the junkyard with the brat today and picked up the fenders and some other little things like the plastic box for the glove compartment a blue door panel and the dash vents. It was a shame to see a brat with such an extravagant paint job so far gone, I bet it was sweet in its day. Because the fenders are much better than mine and need no rust repair so next up is fixing some rust on the door corners and body work then primer and filler.

 

Here are some pic of the brat I got the fenders from with its 80's radness.

 

27502681163_07d91cf653.jpgJunkyard Brat by Luke Hoffman, on Flickr

 

28015255822_b5b589014b.jpgJunkyard Brat 2 by Luke Hoffman, on Flickr

 

28015258282_99a85dfd85.jpgJunkyard Brat 3 by Luke Hoffman, on Flickr

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Finished up the rust repair today as well as a lot of metal bumping on the fenders I picked up the other day. This means the car is almost ready for primer.

 

27591151834_355168c04a.jpgDriver Door Corner Rust by Luke Hoffman, on Flickr

 

28129176621_cf9ca1ae4d.jpgDriver Door Corner Cut by Luke Hoffman, on Flickr

 

Inner door skin was also rusted so I made a new piece for that as well.

 

28102908862_394256d8b6.jpgDriver Door Inner by Luke Hoffman, on Flickr

 

28206732735_0fea642024.jpgDriver door repaired by Luke Hoffman, on Flickr

 

27591348953_1bf1899035.jpgPassenger Door Corner Rust by Luke Hoffman, on Flickr

 

27591432303_e05598ec30.jpgPassenger door repaired by Luke Hoffman, on Flickr

 

27591422463_f398883a04.jpgDriver Fender Pre Work by Luke Hoffman, on Flickr

 

28129101421_abba8255c1.jpgDrivers Fender Roughed Out by Luke Hoffman, on Flickr

 

28173188236_7a7fdede31.jpgPassenger Fender Roughed out by Luke Hoffman, on Flickr

 

28206689155_0dc6d11ec5.jpgFront end by Luke Hoffman, on Flickr

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  • 3 weeks later...

To clean the underbody I used a scrapper and hammer and chisel then wire wheels to get rid of most of the old cracked undercoating, touch up any rust with a grinder or the wire wheel, prepped everything with wax and grease remover or whatever I had laying around, primed and painted then undercoated with 3M undercoating. Lots of time underneath the car and a pretty dirty job but its worth it to keep the underbody from rusting.

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To clean the underbody I used a scrapper and hammer and chisel then wire wheels to get rid of most of the old cracked undercoating, touch up any rust with a grinder or the wire wheel, prepped everything with wax and grease remover or whatever I had laying around, primed and painted then undercoated with 3M undercoating. Lots of time underneath the car and a pretty dirty job but its worth it to keep the underbody from rusting.

 

Awesome. I'm hoping to do the same thing. Thanks!

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  • 1 month later...

Been trying to get everything ready for prime, almost there.

I tried for weeks to get the torsion bar out with no luck so I decided to bite the bullet and drop the whole rear end. While the gas tank and diff are still out I'm going to clean up the rust and undercoat from the cab back so the underbody will be completely undercoated.

After I got the torsion bars lose I lowered the back to where I want it to sit. Trying to get this thing painted before winter so I'm gonna have to wait on lowering the front.

 

28842053063_76f17155d4.jpgUnder bed by Luke Hoffman, on Flickr

 

28842059683_e08aacef66.jpgUnder bed 2 by Luke Hoffman, on Flickr

 

28839546984_0a9b34cb14.jpghover brat by Luke Hoffman, on Flickr

 

28839556804_c3c95f9fb8.jpgRear lowered by Luke Hoffman, on Flickr

 

28839563514_5556ff66ec.jpgFrom the back by Luke Hoffman, on Flickr

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  • 4 weeks later...

Well I got most of the car primed over the past two weekends, didn't have time to clean up the bed or tailgate and some other small parts. It was my first time painting anything bigger than a bike and I think it turned out pretty well. The primer I used was Spi red oxide epoxy.

 

Made a little makeshift paint booth out of a harbor frieght car shelter and some tarps, masked off the bed and the doors and windshield.

 

29943345722_cd36789c2a.jpgRear End Masked by Luke Hoffman, on Flickr

 

Masked off the engine bay and windshield.

 

29762906140_735b0f2908.jpgFront End Masked by Luke Hoffman, on Flickr

 

All primed and unmasked, ready to come out of the makeshift paint booth.

 

29973463861_ab67f8fee5.jpgIn the booth by Luke Hoffman, on Flickr

 

Turned out pretty good and I'm gonna put it back together so I can do some body work.

 

29973461071_b260947a78.jpgPrimed by Luke Hoffman, on Flickr

 

Somethings missing here but it's starting to look more ready.

 

29762888640_0399ff485a.jpgBay primed by Luke Hoffman, on Flickr

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I plan to prime and paint the bed the same as the rest of the car with removable carpet like how it came from the factory. I would've primed it with the rest of the truck but I want to clean up the rust a little better than I had the chance to and wanted to prime it while the weather was still good.

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  • 4 months later...

Tore into the heater and found a huge mouse nest on top of the heater core.

 

This is after I took out the nest, forgot to get a picture of the thing this time.

 

33100286476_e565dddafb.jpgHeater by Luke Hoffman, on Flickr

 

Replaced all the foam and painted all of the flaps in the heater, got the heater core flushed and pressure tested and painted it too. 

 

33141971845_2604ebdf7a.jpgNew Foam by Luke Hoffman, on Flickr

 

All back together

 

32296137974_b639a7e53e.jpgHVAC  back by Luke Hoffman, on Flickr

 

32758986990_bdf680af03.jpgHVAC front by Luke Hoffman, on Flickr

 

My cam had some bad pitting so I got a hydro cam and got a cam grind from Delta cams. I also had the crankshaft polished.

 

33141965875_06d8284897.jpgCrank and Cam by Luke Hoffman, on Flickr

 

Got the block resurfaced as well.

 

32296129264_89c13efb20.jpgResurfaced block by Luke Hoffman, on Flickr

 

Had an issue with some of the piston rings I got sent having too large of an end gap, waiting on a new set and then the engine will finally be going back together!

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