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Old 09-02-2019, 08:26 AM
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Default 8.31.19 & 9.1.19

A few hours Saturday was spend on the interior. I finished up the rear harness and seat support bar and worked on the rear shelf area. I also got a little closer on the center console fit.

Sunday started with the dash. I figured I'd start with something easy and relaxing. I really like the race car style dashes I have seen in many vintage GT40's. This is my attempt. Not done, but close.

Car #069-146.jpg

Car #069-147.jpg

From there I concentrated on the front end of the car. I wanted to get the front end as close as possible to done. I needed to get the alignment close so I can finish weld the steering quick disconnect. I've never had a professional front end alignment on a VW before. I've always been able to get real close with a long straight edge and a tape measure. This time is no different.

I also mocked up my side markers and front turn signals. The markers are because I know some states require them and I'd like this car to be able to go anywhere in the future and be legal, or darn close. The front turn signals I used because I have seen the beehive style on several cars from the 60's and 70's (plus I had some in stock). I will also be using the polycarb covers over the headlights.

Car #069-148.jpg

Next I started to modify a pedal assembly. I needed to shorten them slightly and angle them more toward the driver. I just lap them over on the left side. This gives me 2 sides to weld and also moves them over to the left slightly to allow more room between the brake pedal and gas pedal. This worked well in the #114 car. I'll get them welded up today and cleaned up ready for install. Also had to make a new pedal stop and get it in place. The accelerator pedal will just be a roller style like I have used in the past.

Car #069-149.jpg

Car #069-150.jpg
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Old 09-02-2019, 11:02 PM
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Default 9.2.19 Labor Day

Spent the entire day on wiring. 12 hrs worth and still have a lot more to do. This time I am going to keep track of just how many hours it takes to completely rewire a Sterling. No photos, nothing exciting to report.
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Old 09-09-2019, 09:38 AM
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Default 9.7.19 & 9.8.19

Wiring continues, probably have another 6 hours into it.

I started plumbing up the canopy, still waiting on a fitting before I can test it.

I made some brackets for my rear taillights. Keeping them simple and inexpensive. These use 1157 bulbs. I didn't want LED since I'm trying to make it a vintage recreation. I like the simplicity of the 917 Porsche Gulf Racing car. This is my version for the Sterling.

Car #069-155.jpg

Car #069-158.jpg

Car #069-160.jpg

Car #069-162.jpg

Car #069-161.jpg

Did a bunch of other misc. things over the weekend as well.
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Old 09-09-2019, 10:56 AM
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Very neat.
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Old 09-11-2019, 10:21 PM
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Default 9.11.19

Been putting in a couple hours each night after work. Nothing major done just little things here and there. Tonight I finished up my plumbing for the top and got the seats sprayed out with epoxy primer. One seat I will use to make a mold from. I need two seats for this car since the 2 original seats will be used in car #S068. Tomorrow I will pick up some jack oil so I can test my system.

Something I said I wasn't going to do but just couldn't help myself, I ordered all new gauges. Originally I just wanted it to look good but I have decided if I'm going to work this hard on it I might as well make sure it all works perfectly. GPS driven Speedo, new 7k Tach, new Volt meter and Oil pressure gauge with a new sending unit. I spent a lot of time looking for best prices and still spent about $550. It will be worth it in the long run. I also ordered a fuel tank today.
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Old 09-14-2019, 08:13 AM
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Default 9.13.19

Work continues at a steady pace. Working on the car every chance I get. I finished and tested the plumbing. After replacing one leaking fitting, everything seems good to go.

I disassembled the lifting arms to alter, sand and get ready for paint. I had to change the stud where the cylinder attached to an 8mm x 1.25 to match the cylinder. Minor repair was also needed to the base plate where the side plate had come off the bracket. Most everything was sanded back to metal, etch primed, and is ready for priming and paint. I will test it fully before I paint everything to ensure the cylinders will work with a full load on them. I can't imagine they won't be ok but ya just never know.

Wiring continues! I know I said I was going to keep track, but I just keep doing a hour or two here and there. I'm still waiting on indicator lights and a usb port to call the dash done. I will test the harness once it is complete before paint.

Motor ..... I have 3 choices. I have a freshly built 1776 and 1915, both that I built, and the motor I got from Brian when I bought the car. I'm trying to get this car finished before BugJam in November. The 1776 I built has never been run. The 1915 has been run and had its cam run in. I don't know anything about the guy who helped Brian build his motor, so a complete disassembly will be a smart thing to do. I think being that the theme of the car is a vintage race car, bigger is better! I'll have to do a carb swap and replace the dual Kadrons with a pair of Dellortos, change around the tins and install the exhaust. I think that will require the least amount of time for a motor I know will run good. I had other plans for the 1915, but oh well, nothing is ever etched in stone!

Car #069-171.jpg

Car #069-172.jpg

Car #069-168.jpg

It's no Porsche but, it is a Sterling after all. A Gulf-Sterling even!

Car #069-169.jpg

Also got the pedals welded up. I couldn't for the life of me get the pedals apart to replace the brake pedal return spring! Copious amounts of heat and penetrating oil didn't help even a little. And to think, they are only 45 or so years old. I can't imagine why they wouldn't come apart. Note to self: Next time try and disassemble the pedals before you cut and weld them. I'm to far along now to grab another set and start over. I guess I'll have to come up with another solution. No worries.
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Last edited by ratrog64; 09-14-2019 at 08:27 AM.
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Old 09-14-2019, 09:16 PM
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Default 9.14.19

Started out the morning bolting the body to the pan and then adding a pedal return spring to the pedals. Then it was up to the shop as Saturdays are often work on Rays Car days. I've got his front end up on jack stands and while doing some sanding I noticed some bouncing of the nose. We decided to make what the UK boys call a flopper stopper. Seemed to do the trick nicely. After spending a few hours on Rays car I got back to the garage and made one for the #S069 car too. A little different then we made his but some basic idea. Not the prettiest welds I've ever done. But figuring where and how I was welding it not too bad.

Car #069-173.jpg

Car #069-176.jpg

Car #069-175.jpg
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Old 09-17-2019, 07:09 PM
Nic Nic is offline
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Are you leaving the engine exposed like the Porsche 917?
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  #69 (permalink)  
Old 09-17-2019, 08:15 PM
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Quote:
Originally Posted by Nic View Post
Are you leaving the engine exposed like the Porsche 917?
Yes Sir. Other then the tins etc, what you see is what you get.
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Old 09-18-2019, 08:22 PM
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Default 9.18.19

Finished up a little body work on the dash tonight then sprayed out 3 heavy coats of high build primer. Since it was mostly black it was tough to see the pin holes in the glass. Now with the primer I will go back and fill in a bunch of pin holes and block it out.

Car #069-177.jpg

Car #069-178.jpg

I have been working a little less on the car the last few days since my hip (which I broke in Feb) has been giving me some grief.
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