"D-check" (major maintenance check) for my MkII Roadster

[erne.castro]

Hi all,

I'm planning on doing a major maintenance check on my MkII Raodster. I've purchased the car from a previous owner that was not very keen with it and the builder didn't do a great job either (mainly on cosmetic details).

My plan is to:


Remove the dashboard. Probably replace it with a brand new FFR dashboard with glove box.
Remove all remains of AC/Heater (previous owners install an oversize heater/AC and then took it apart but left parts of the system install). My idea is not install a new heater (I live in Houston, TX).
Re-do all the electric circuit. I'm not planning on installing pre-build electric wire harness but do a custom installation using all IP67 connectors.
Re-do fuel line as it location is not good.
Remove all remains of stereo/speakers.
Re-finish all chrome parts (sending them to a chroming store).
Upgrade the brake system. Now it has a manual breaking system with just one circuit. I want to keep it manual, but add a two circuit system for safety.
Repaint all parts of the frame that is not in good condition.
Check with more detail (after taking the body) all the mechanical parts such as suspensions, brakes, etc.


For this the biggest thing I'm going to remove is the body.

What I would like to get from y'all is some tips or advices about this. I'm an Electronic Engineer so I have some technical background and I have work with cars before (biggest thing I did in the past is rebuilding a car engine), but never to this extend in the sense of taking apart the body and all electric circuit.

Any idea comments/suggestion? Is this a crazy endeavor?

[JohnnyB]

Sounds like a good plan. Removing the body really isn’t very hard and it will give you the opportunity to inspect and upgrade as needed. It’s also a good way to make the car yours. There is something to be said for that. The only hitch I see is that the new dash won’t fit a Mark II. The steering shaft was moved to the left on the Mark IIIs.
While your at it be sure to check your shocks for recalls. See this thread from Eric Treves
https://thefactoryfiveforum.com/showthread.php?34123-If-you-plan-on-selling-your-unfinished-car-a-little-bit-of-a-rant

[Big Blocker]

Just a few notes on your plan . . .

Remove the dashboard. Probably replace it with a brand new FFR dashboard with glove box. The newer dash from F5 won't fit the earlier cars

Remove all remains of AC/Heater (previous owners install an oversize heater/AC and then took it apart but left parts of the system install). My idea is not install a new heater (I live in Houston, TX). Seat heaters are a good choice if you don't want the trouble of a complete heater system

Re-do all the electric circuit. I'm not planning on installing pre-build electric wire harness but do a custom installation using all IP67 connectors. Might be a bit of overkill to wire everything with IP67 connectors, these cars have been running on the road for years with just the everyday crimp on electrical connectors and weatherpacs at the area that are exposed to the elements

Re-do fuel line as it location is not good.

Remove all remains of stereo/speakers. this is a personal choice completely - most consider the side pipes the stereo system . . .

Re-finish all chrome parts (sending them to a chroming store). Chroming is getting harder and harder to get done because of environmental concerns - powder coating is a great alternative.

Upgrade the brake system. Now it has a manual breaking system with just one circuit. I want to keep it manual, but add a two circuit system for safety. Not sure what you mean by a one circuit braking system, almost every master cylinder now-a-days is a dual unit with front n back separated.

Repaint all parts of the frame that is not in good condition. Por15 is your friend here . . .

Check with more detail (after taking the body) all the mechanical parts such as suspensions, brakes, etc.

Being a MKII, I'd suggest that you take the front control arms apart completely and check for damage under the end links where they ride on the cross shaft - early cars were known for lack of lubrication capabilities caused fatigue failures.
Check for the "brand" of shocks, there were numerous recalls for certain units and the manufacturers will still honor the upgrades if you send them in. Check (front) spring coil count, Bilstein had an issue with too many coils and spring bind.

Good luck . . .

Doc

[erne.castro]

Thanks guys for the replys!

Regarding the braking system, mine does not have a dual unit. Just one reservoir and front and back are not separated. A damage to a break line will draing the whole system and leave the car with no more than engine and hand break!

Regarding that dashboard, do you know of an alternative? I may very well do mine, but I don't want to throw in to much manual work as I'm planning to have the car back in running conditions by spring.

[Walt]

Hi, what part of Houston are you in?
Walt

[erne.castro]

Actually I'm in Fulshear, Southwest of Houston.

[CraigS]

You could do another aluminum dash. Ck w/ FFR but I think they sell them w/o holes. If not, take yours out, remove instruments and go to a sheet metal shop to have them make a copy. You could also ck w/ Bill here.
http://www.ffmetal.com/

[Walt]

Ok, im northwest a ways, but if you need help would be happy to come down!
Walt

[erne.castro]

Thanks a lot of all the support/help. I'm starting to take it apart, hopefully in two weeks I will have all in parts (well, most of it).

If I need help I will let you know, maybe to take out the body!

[Walt]

This coming Saturday the Houston Cobra Club is doing a lunch at the Bramen winery at Richmond at 11 am, i plan on being there if you have a chance come by and meet some folks.
Hope to see you there. Sending you a pm with my info.
Walt