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 Post subject: at long last... '76 Opel by Isuzu
PostPosted: Thu Sep 27, 2012 9:37 pm 

Joined: Sun Apr 20, 2008 12:37 pm
Posts: 548
Location: Sugarhouse, Utah
Well, the day finally came, and I am just totally excited about it... I finally have my car, so now comes the obligatory build thread. As the title states, this is a 1976 Opel by Isuzu that I bought from a member here (and on planetisuzoo). I intend to put it back on the road first, and fix things little by little once it's driveable. Anyway, on to some pics...




hauler backing down the street to unload
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car on the trailer
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sitting in its new home with a munchkin in the background
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buncha stuff in the trunk
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now honestly, I wasn't expecting to see this, but I guess that was just a question I forgot to ask.
the trunk after everything was out of it
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gonna be a lot of work there :cry:

this was awesome, it even came with the original owner's manual!
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and keytag
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those that know these cars know that these grille mounting points are always destroyed
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keeping good company
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original engine in the crate
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danglin' :wink:
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and on the stand
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that last one got a little fuzzy 'cause I was running out of light. At first, I couldn't get the engine to turn over at all, but I shot some wd-40 in the cylinders and let it sit for a minute, then I tapped on the pistons with the handle of a hammer while I put pressure on the wrench, and pretty soon it freed right up. Still gonna pull it apart and rebuild it, though. Don't want to have to pull it all apart later for a set of rings I should have done in the first place.

Well, that's as far as it got today. I'll keep you posted.

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 Post subject: Re: at long last... '76 Opel by Isuzu
PostPosted: Fri Sep 28, 2012 7:03 pm 

Joined: Sun Apr 20, 2008 12:37 pm
Posts: 548
Location: Sugarhouse, Utah
A little more progress today, but not a lot...

started to clean up the block with a wire brush
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got tired of that, so I whipped out the wire wheel, and 5 minutes later...
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then I started pulling pistons out
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all 4 out
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gonna clean 'em up with a hone and see where that gets me
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I think they'll be alright.

I'll get to it a little more tomorrow.

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 Post subject: Re: at long last... '76 Opel by Isuzu
PostPosted: Fri Sep 28, 2012 7:20 pm 
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Joined: Sat Mar 24, 2007 8:45 pm
Posts: 2582
we all breath a collective sigh of relief 8)


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 Post subject: Re: at long last... '76 Opel by Isuzu
PostPosted: Fri Sep 28, 2012 9:34 pm 

Joined: Sun Apr 20, 2008 12:37 pm
Posts: 548
Location: Sugarhouse, Utah
yeah, now that I actually found one, I'll have to find something else to talk about endlessly... :lol:

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 Post subject: Re: at long last... '76 Opel by Isuzu
PostPosted: Sat Sep 29, 2012 8:25 pm 

Joined: Sun Apr 20, 2008 12:37 pm
Posts: 548
Location: Sugarhouse, Utah
A little more progress to report today.


All ready for the day
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first order of business, get the crank out. so, out comes the rear main seal
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off come the main caps
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got it out and started to clean it up a little, I think it'll live
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then I decided to work on the front of the engine
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took off the tensioner and took the wire wheel to the block
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cleaned up the threads
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cleaned up the parts and put them back on
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decided to go through all the parts that came with it to see what I need to buy. found some interesting stuff in there
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brand new head
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the ship date on the box is from 1988, I'm betting that's about how long this car has been off the road.

brand new gas flap :shock:
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I hope the carb's gonna be ok, but I dunno
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looks kinda scary to me, might have to find another one.

then I took the hone to the cylinders
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they look like they'll be fine

went out and grabbed some lunch, and while I was out, I picked up my new trunk floor
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I think all the moisture got into the trunk here
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there is a hole about an inch long right next to the edge of the rubber, and it leads straight into the trunk. I can't really be mad at the seller for this, I'm not sure he knew how bad it was. I think everything was just put in the trunk for safe keeping and then the car was stored outside for 20 years or so.

then I spent the rest of the day cleaning pistons
Image
let them soak in a can of carb dip for a while, then attacked them with a wire brush.
more tomorrow, I guess.

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 Post subject: Re: at long last... '76 Opel by Isuzu
PostPosted: Sun Sep 30, 2012 6:28 pm 

Joined: Sun Apr 20, 2008 12:37 pm
Posts: 548
Location: Sugarhouse, Utah
I didn't get much time on the car today, but here it is:
I cleaned the timng cover.
Exciting, huh?
Here's what I started with:
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I think that distibutor's brand new, too :tu:

So I pulled the distributor out, sprayed the cover with degreaser, and started working on it with a soft brush. It worked, but not as well as I wanted, so I grabbed the carb dip again. that actually worked pretty well, but there was still some stubborn stuff I had to use the wire brush on. Here's how it came out:
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not perfect, but not bad compared to what it was. maybe I'll do a little more later.

test fit
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looks pretty good.
well, that was all the time I got on it today.
talk to you later.

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 Post subject: Re: at long last... '76 Opel by Isuzu
PostPosted: Sun Sep 30, 2012 6:55 pm 
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Joined: Sat Mar 24, 2007 8:45 pm
Posts: 2582
you're also taking pictures, and that counts for something too :lol:


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 Post subject: Re: at long last... '76 Opel by Isuzu
PostPosted: Sun Sep 30, 2012 7:01 pm 

Joined: Sun Apr 20, 2008 12:37 pm
Posts: 548
Location: Sugarhouse, Utah
I know people love pics! I'm going to end up with a minor dilemma, though. eventually someone's gonna want a video of start-up, and I have no idea how to get video from the camera to the forum. I guess I'm gonna have to learn that one.

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 Post subject: Re: at long last... '76 Opel by Isuzu
PostPosted: Wed Oct 03, 2012 3:24 pm 
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Joined: Sun Sep 26, 2010 11:46 pm
Posts: 692
Location: Magna, UT
Glad you finally got here :)

On the video, if you can save it to your computer, then you can upload to youtube or photobucket and share the link here.

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 Post subject: Re: at long last... '76 Opel by Isuzu
PostPosted: Fri Oct 05, 2012 4:34 pm 

Joined: Sun Apr 20, 2008 12:37 pm
Posts: 548
Location: Sugarhouse, Utah
sorry there hasn't been a lot of progress for the last few days, but I haven't gotten much time on it in the evenings. But I did order the rebuild kit for the engine, so while I was waiting for it to show up I decided to try and figure out why the brakes weren't working. there was no fluid to begin with, so I put some in to see what was going to leak. I didn't really notice any leaks, but no pedal either. So I decided to pull off the master cylinder to see what was up.

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once I got it off, it was pretty obvious that the piston was stuck in place

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so I tapped on it a little bit, and got it to free up, so I put it back on. then I went through and bled the whole system. it did pump up and feel pretty solid, but you should see the color of the fluid :shock: I'll flush it out with some fresh fluid later and see if it holds. Seems ok for now, though. that's all I did lately, but there's more coming. stay tuned.

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 Post subject: Re: at long last... '76 Opel by Isuzu
PostPosted: Sat Oct 06, 2012 6:57 pm 

Joined: Sun Apr 20, 2008 12:37 pm
Posts: 548
Location: Sugarhouse, Utah
ok, today's update:


here's what I get for $240 at the machine shop
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rings, bearings, full gasket set, & oil pump.

started wiping down the block, and ended up with a helper
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she got bored pretty quick, though.

after I got it all clean, I finished cleaning up the crank and put a new pilot bearing in it
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that also came with the car

put main bearings and thrust washers in the block
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put the new rear main seal on the crank and set it in place
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installed the other half of the main bearings and torqued the caps to 72 ft.-lbs.
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then installed new rings and put the pistons in
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all 4 in
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don't worry, I did get the rod bearings in there, too. I just didn't take any pics of that.
I would have liked to do more today, but I think it was reasonably productive. on another note, I noticed my master cylinder was leaking out the back where it bolts to the booster. anybody know where I can get a rebuild kit for it?

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 Post subject: Re: at long last... '76 Opel by Isuzu
PostPosted: Mon Oct 08, 2012 9:15 pm 

Joined: Sun Apr 20, 2008 12:37 pm
Posts: 548
Location: Sugarhouse, Utah
so here's the update:
let's start with yesterday, when I pulled my brand new head out of the box and started cleaning. it was pretty time consuming, but I didn't want to leave all the sticky goo there and risk it plugging something up.
before:
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after:
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so here's an issue I've got to figure out pretty quick. the old head has a nipple in it for the coolant, the new one didn't come with that, just the smooth hole where it's supposed to go. what do I do? do I get a new one? and where? can the old one be re-used safely? how would I get it out? how would I put the new one in so it wouldn't leak?
Image

so anyway, after I cleaned up the head, I installed new valve seals, cleaned up the valves, and put them in. all except 2. turns out, I was missing a couple retainers. so this morning I got some from a machine shop, and finished installing the other 2 valves.
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so then I cleaned up the rockers and shafts, installed them, and set the valve timing
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put a new front main seal in the timing cover, put on the new oil pump, put the distributor back in
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and put the cover on with a new water pump. I wasn't sure about the old one, and I didn't want to have to change it later.
Image

then I cleaned up the valve cover
before:
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after:
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not great, but it'll have to do for now. the first time I see a better one in the junkyard, it's coming home with me. I'm not happy about having to put this on this engine.

but I put it on
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then I flipped over the engine, and bolted on the oil pump pickup
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then I started transferring the studs from the old head to the new one.
Image
that's kinda where I left off.

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 Post subject: Re: at long last... '76 Opel by Isuzu
PostPosted: Mon Oct 08, 2012 11:54 pm 

Joined: Wed Dec 02, 2009 4:24 am
Posts: 103
Location: Lobethal, South Australia
nice work, going to be very clean when your done! i like these Opel versions of the Gemini we got here in Australia, just enough differences to make them look similar but different at the same time!
going to keep it the origional orange colour?


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 Post subject: Re: at long last... '76 Opel by Isuzu
PostPosted: Tue Oct 09, 2012 7:42 am 

Joined: Sun Apr 20, 2008 12:37 pm
Posts: 548
Location: Sugarhouse, Utah
yeah, I like the color, but eventually it's going to need a repaint after all the rust is fixed. I want to do it in the original color, and with the correct side stripes and whatever stickers would be there from the factory. basically, when I get to that point, I want it to look like brand new, but that's down the road a little.

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Last edited by opelboy76 on Tue Oct 09, 2012 9:52 am, edited 1 time in total.

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 Post subject: Re: at long last... '76 Opel by Isuzu
PostPosted: Tue Oct 09, 2012 8:42 am 
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Joined: Sat Mar 24, 2007 8:45 pm
Posts: 2582
always thought that engine looked cool..


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 Post subject: Re: at long last... '76 Opel by Isuzu
PostPosted: Wed Oct 10, 2012 9:31 pm 

Joined: Sun Apr 20, 2008 12:37 pm
Posts: 548
Location: Sugarhouse, Utah
ok, been a couple days, so here's what you missed... I finished getting all the studs transferred to the new head, then I realized I had another issue:
Image
so I looked around the junkyard to see if I could come up with something, and found one off an 89 trooper that fit, so I grabbed it and put it on:
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I decided the best way to deal with the coolant nipple problem was going to be for me to cut it out of the old head. the head was junk anyway, so I took the grinder to it:
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got it out safely
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mixed up some Quiksteel, smeared it on the nipple as thin as I could, and tapped it into place.
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I think it's going to be fine.

so then I tried to clean the oil pan:
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but I gave up and sent it out to be hot-tanked. I'll get it back friday, and hopefully it'll look better.

in the meantime, I decided to tackle the rear brakes. the wheel cylinder on the left was leaking, and the right didn't seem to be doing much of anything, so I put on new wheel cylinders and new shoes while I was at it. so now the rear brakes are done, and they have clean fluid going to them, too!
Image

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 Post subject: Re: at long last... '76 Opel by Isuzu
PostPosted: Wed Oct 10, 2012 9:34 pm 

Joined: Sun Apr 20, 2008 12:37 pm
Posts: 548
Location: Sugarhouse, Utah
oh, I took the master cylinder apart and cleaned it up, too. so far, no leaks. but I think I have one at the right front caliper. maybe I'll look into that tomorrow.

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 Post subject: Re: at long last... '76 Opel by Isuzu
PostPosted: Thu Oct 11, 2012 9:21 pm 

Joined: Sun Apr 20, 2008 12:37 pm
Posts: 548
Location: Sugarhouse, Utah
ok, well, I took a look at the front brake on the right side, and the pads were paper thin, so I have a set coming in from California. took off the caliper to check it out, but I couldn't really see any leaks. maybe it was just a mess I made when I was bleeding the system. while I was working there, I figured out why the car came with a new steering rack... you can shake the tire back and forth about a half inch each way, and it's all in the rack. more work I wasn't planning on... now I'm afraid to find out why it came with a new gas tank. I hope there aren't too many more hidden surprises on this car, but by now I think I've found them all :roll:

well, the shop called me today and said my oil pan was done, so I went and picked it up:
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still not perfect, but a lot better than it was, and at least I know nothing crusty's gonna come off and get into the engine. overall, I'm happy with it.

so I gave it a fresh coat of paint
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slapped it on
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then I stood the engine back up, cleaned up the intake the best I could, and put it on. I had been soaking the carb with wd40 for a few days, and working the butterflies back and forth to the point where I feel good about it. I scrubbed the bottom of it with a wire brush, wiped it all down, and put it on, too
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manifold and carb on
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now if I can just figure out the spaghetti mess of vacuum lines, we'll be ok.

then I threw the exhaust manifold on, too
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I think this thing's just about ready to go in! but I'm gonna deal with the steering rack first. probably tear into that tomorrow.

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 Post subject: Re: at long last... '76 Opel by Isuzu
PostPosted: Fri Oct 12, 2012 1:09 am 

Joined: Wed Dec 02, 2009 4:24 am
Posts: 103
Location: Lobethal, South Australia
looking real nice so far, you work a hell of a lot quicker than i do though!


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 Post subject: Re: at long last... '76 Opel by Isuzu
PostPosted: Fri Oct 12, 2012 7:42 am 

Joined: Sun Apr 20, 2008 12:37 pm
Posts: 548
Location: Sugarhouse, Utah
mrflibbles wrote:
looking real nice so far, you work a hell of a lot quicker than i do though!


this is abnormally fast for me. I took a week of vacation this week so I gould try to get this on the road. probably not gonna make it by the time I have to go back to work, though. but I am happy with the progress I've been making so far.

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