2 sets of rear axle assemblies built up today. Should be installed later this week.

Al
Georgia

Remounted the brake pivot pin on the left rear backing plate. Original plate that prevents wheel cylinder piston from coming out of the cylinder had a tab that was bent. I was able to remove rear piston without removing cylinder. A good replacement plate was brazed in on Monday before we assembled the assembly.

Rebuilt right rear brake wheel cylinder due to leakage. Honed and cleaned housing, then installed rebuild kit. Pistons were cleaned and polished.

Decided to rebuild left rear brake wheel cylinder to ensure all was good. Found front piston was stuck. Removed piston with light tap. Honed and cleaned housing, then installed rebuild kit. Pistons were cleaned and polished.

They are now ready for installation again.

Al
Georgia

Morning session of working on More Door is over. Time for lunch.

Install both rear axle assemblies.

Hooked up ratchet strap to both rear shock mounts and snugged strap up. Loosened both control arms' bracket bolts on the differential and strap slackened. Tightened strap to ensure brackets were seated against differential. Torqued bracket horizontal bolts first, then the vertical bolts. That should fix the alignment difficulty Goodyear was having trying to align the car. We will see once I have it back on the road and in their shop for another check.

Installed both balanced drive shafts.

Installed right brake parts and line.

More to be done this afternoon.

Al
Georgia

Due to rain shelf building for the 40' container was stopped. I went back to work on the More Door and installed the left rear brakes.

Will inspect and hone/reseal front wheel cylinders tomorrow afternoon.

Al
Georgia

Pulled front wheels' brake cylinders for inspection and cleaning. Reason, these cylinders (and entire front brake package & hubs) were put on my Coupe 8 years ago, then removed for disc brake upgrade. Brake fluid never was introduced into the Couple's brake system after all its brake line work.

Nothing was found wrong with cylinder parts, but I did a hone on them and polished the pistons. I will install them tomorrow. Then I will address the improperly routed dual master brake lines. Photo shows the lines as currently installed. Not a good line routing. I will rout them like GM did on the 67 - 69 Vairs. All parts on hand.

AmMel: got those stumps removed today. That is why cylinders didn't get installed. I had a little shovel help from the neighbor.

Al
Georgia

Nice!
The method is not as fun, but definitely more friendly to cars and houses.

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WA. state, 1 mile south of the Canadian border, I am not at the end of the world, but you can see it from here.

Just finished reconfiguring MC lines in trunk reconfigured. Still need to cut and flare rear line, then connect to the added bulkhead fitting.

Headed out to drain Powerglide to replace the TV lever we repaired last year.

Al
Georgia

Much nicer! Don't forget to add the warning light!

MODERATOR
Sea Mountain, between Charleston Harbor and Coos Bay! SW Oregon Coast
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Yes. Going to put it next to the park brake warn light.

Al
Georgia

Removed powerglide pan and removed the repaired TV lever. I compared the 2 levers and found the repaired lever splines are about 5 degrees off from the replacement lever. May explain why engine jumps to 1000 rpm when selected to low from drive. Accerator rods are set up to the 66 Assembly Manual.

Also found reason for PG fluid leaking around bolts. The inner edge of pan cut the gasket, even though outside edge showed acceptable gasket compression. Edge of pan is bent down for some unknown reason. I have a replacement pan available, along with the pan reinforcement plate from Clark's. I purchased serrated head bolts of proper length. I did not like the slightly longer grade 5 bolts Clark's supplied with the reinforcement plate.

Donna replaced the wheel wheel trim screws. The ones in the car were so bad, the chrome was gone and rust was there. Wire buprshed. Them and they were black head screws.

Got to cold, windy, and raining to keep going. I covered transmission with a trash bad and tied it on to keep it in place.

Al
Georgia

Yesterday, Rick and I got the brakes adjusted on the Vair following all the work done on them. We attempted to utilize the existing steel line to the rear for the new bulkhead fitting. The PO bent the original single MC 1/4" rear line where it could not be used by a simple cut back and declare. We tried to cut it back to add a union and short 90 degree line to the fitting, but the Crafttsman flaring tool would slip on the line during flaring process. Decision made to replace entire line with new copper-nickel line. This also gave me th opportunity to properly route line where it was not tangled around park brake cable and body harness. Line was routed, flared and connected. Will be serviced and bled later this week.

I will find a way to secure lines and harness in tunnel area since 3 clips are pulled out of the floor pan.

Inspected replacement PG transmission pan and tapped out bolt holes that were bent towards transmission. Reinforcement plate will be used when pan and new gaskets installed today.

Al
Georgia

Donna and I got busy on the More Door today.

Installed replacement TV lever in PG transmission. Connected cable to PG. Installed pan, new gasket and reinforcement plate. Use new serrated head bolts to secure it all. Connected dipstick/fill tube to pan. Serviced transmission with 3 quarts of fluid and will recheck level after first drive. Connected aft accelerator rod to TV lever and throttle crosshaft per 66 manual supplement requirements. Connected forward accelerator rod to TV lever per manual. Transmission work is done.

Connected forward parking brake cable to aft cable. Connected spring. Adjusted cable of the park brake handle throw to my liking. Cable removed to untangle old brake line from it.

Installed defroster transition duct and floor diverter. Both removed for brake line replacement.

Removed left heater hose. and cut it back 5 inches. It was a bit long and had fallen where it could lightly rub driveshaft.

Tightened oil pan bolts as a small leak was evident there.

Tomorrow will be to secure lines and harnesses inside the tunnel. It will require adding a few clips or clamps. Also will look at standardizing screws that hold panels on. Right now there are 3 sizes. May use quik sert nuts (blind nuts) and washer head bolts to solve issue.

Al
Georgia

Heavy rains today, so not much was done. We did get the tunnel lines secured. We had to add 2 clips and secure the very aft original one. Drilled 1/8" holes and run a #6 screw to secure clip with washers and nuts. Then we ty-rapped the wire harnesses and PG shift cable to keep them from moving around. Heat duct was inspected and no repairs needed. Rear seat air port was re-lined with adhesive foam rubber. Heat duct will be put on tomorrow.

Al
Georgia

Rick helped me finish up Vair today.

Brakes were bled and good pedal was achieved

Heater duct was installed in tunnel and tunnel pans installed. We used sheet metal screw clips on the oversize holes to return back to the same screws on the panel.

Engine was started and checked out for being to high of an idle. Removed the 5 turns the manual called out to be backed off the accelerator rod during the adjustment. Idle was fine then. Pedal function is fine.

Took a trip in the Vair to Molly McPhersons for supper with Donna and Rick. Vair operated fine. Photo shows both our Vairs parked at the eatery.

Rough roads aggravate the vibration issue around 66 mph. But then again it does on my other newer vehicles. On the interstate, it is a great riding car at 70 to 80 mph. Vibration issue is considered resolved. Driveshaft and wheel bearings created the bounce in the right rear, which is no longer there.

On to installing a radio in the car. Donna wants something to listen to without being a boombox in the front seat. I have the parts to do it. Now I have all the major reliability tasks done on the Vair, I can work on the nice to have items.

Al
Georgia

Put speakers in the rear shelf!! Mellows anything! Distance is your friend!

MODERATOR
Sea Mountain, between Charleston Harbor and Coos Bay! SW Oregon Coast
Click HERE for My Website...Click HERE for My TechPages!
...............110-PG.................................................Webered-Turbo

Lane66m Wrote:
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> Rick helped me finish up Vair today.
> . . . . . . . . . . . . . . . . . . . . . . .
> Took a trip in the Vair to Molly McPhersons for supper with Donna and Rick. Vair operated fine. Photo shows both our Vairs parked at the eatery.
>
> . . . . . . . . . . . . . . . . . . . .



Nice Pair-O-Vairs right there, Al.

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WA. state, 1 mile south of the Canadian border, I am not at the end of the world, but you can see it from here.

Yep. You don't see many More Doors parked in a town together unless at a Corvair function.

Al
Georgia

That's a good picture!

I've enjoyed the thread. Thank you!

Doug
65 Monza
Cincy, OH

Looking good!

Donna washed the More Door today. You couldn't tell from last nights picture but it was pollen laden. Pine trees doing their mating thing.

Pulled out the JVC radio and the single DIN radio under dash mount. I got the unit fitted to the case, then the fun began. This radio was an aftermarket Silverado truck radio, Donna took out when the truck was traded a few years back (before we got together). Needless to say, I hate working wiring after someone else has done their thing. Since it had an unusable 20 pin connector (no mate), it got chopped off downstream of the splices that were used. I have started to re-pin the wires. I will be using 2 connectors. One 8 pin for the speaker wires and one 9 pin to do the rest of the wires.

Had to stop to work on radio in order to prep another stump for burning.

Al
Georgia