Some times it's the little things. As I have been fully occupied organizing the Shannon's Classic Car Show 2021 (see here - https://heinkelscooter.blogspot.com/2021/04/shannons-classic-car-show-sunday-18th.html ), I have not been able to progress the restoration as quickly as I had hoped. I have also been distracted by a few little side projects.
I acquired a German Salzkotten petrol can which popped up for sale just near me. It was a little worn out and missing the cap, but was worth picking up.
It tied up really well and after a respray looks really great.
I've also been tidying up the engine bay. There was a lot of surface rust and grime all over the firewall. I ground off the rust with a wire wheel, stripped off some of the poorly applied black paint that covered everything in the engine bay. Currently the firewall is coated in a pale green primer. It's surprisingly close to the original light green color the car was painted.
I have turned to the electric instruments. I dismantled, cleaned up and reinstalled the windscreen wiper, checked the horn (which looked in great condition) and cleaned it up. The horn had been coated in flat black paint which proved easy enough to scrape off, revealing the Bosch label.
The electric radiator fan has also been cleaned up and reinstalled in its frame.
The fuel tank has been reinstalled but unfortunately the sender is irreparable. This sender mechanism is very different from 'normal' senders. It basically operates as low fuel warning system, activating a light on the dashboard when the fuel button is pressed. It had three settings - full, half full and low. I think an electronic low fuel sensor is a suitable option.
Brake lights are installed.
There were some terrible tears in the original headliner. I've simply put patches on the tears to prevent them getting worse.
In April I set about the task of removing the wishbones on the front wheels as the silent blocks have completely disintegrated, however, all four bolts proved to be absolutely immovable. There was nothing for it but time with the blowtorch and spanner.
Things were hotting up!
But after three weekends of on and off heat treatment without any sign of movement I became convinced that someone has welded these bolts on. I called in the help of the Magnificent Ken, who did the rust repairs on the car, to have a look at them.
Hilariously, Ken put the spanner to the first bolt and gave a bit of a push and BOOM! The bolt slipped. The look on my face must have been priceless! Each of the four bolts came off without further trouble. I can only say that my work with the blowtorch over previous weekends had 'loosened' them.
After a little more spannering the wishbones were finally out and the silent blocks could be removed. The front left hand silent block had completely lost all its rubber coating. The rear left hand silent block had only partial covering. These silent blocks are no longer available from any source.
The bushings were replaced with modern Nolathane bushings. These are available part number SPF2230K (genuine Toyota bushes 90385-150002). The do need a little cutting to fit the wishbone.
A couple of hours each side and they were done.
Which allowed me to put together some of the other suspension parts. This is only a test fitting as I'll need to disconnect the suspension again when I put the engine back in.
Other things I'm working through:
1. The electrics. I have not had an opportunity to take the old wiring loom in for replacement. I am going to take it to Yesteryear Parts https://yesteryearparts.com.au/
2. Once I have the wiring I can get the electrics dealt with.
3. I am waiting on a couple of engine mounts from Germany
4. The engine rebuild!
5. When the engine is done, then the real reassembly starts.
It still seems like I have a lot to do!
Previous update - https://dkwautounionproject.blogspot.com/2021/02/dkw-meisterklasse-project-update.html