Overhauling a Opel GT Rear Diff. Unit

Project Update,

The Motor being rebuilt is from a 75 Manta used with Fuel Injection

While the 75 Block is best for EFI as the Block has a Rear Port to feed the Heater box,,

also the 75 block uses " Cast" Rods that's not Good/// So the machine shop will be swapping out with 1.9 forged rods... The 1.9 head I'll will be using stock 2.0 Exhaust valves and seats/2.0 intakes/Guides, and Stock 2.0 cam,, so I don't have problems setting Total advance timing,, also lightly ported... That's being done at a Machine shop on Cape Cod.

The Transmission I'll be using will be a Five Speed Getrag, that a Good friend Norbert has sent to me from Germany, some time last year with a Special Gear Selector Console.. should be pretty nice

The Front Suspension ready to Go back, after The Motor.... so I have time.now, to strip and repaint the engine bay back to the matching Yellow color... Am not Big on Black Engine Bays,, no,no takes away from the details... So Big Job now getting the Engine Bay Prep... and to get the Complete GT Mask and covered for the Paint and sanding Over Spray..Etc ..

Stay tuned to this channel...for more update's

Quote from Gary

It's too bad that this thread wasn't started in the "Projects" section.

Projects is a Blog format where you start your project and then add "Articles" under that project. Comments are placed below the article, not between the article posts and new Articles could be added as you go to a different phase of your project.

I really need to do a "How to navigate" page.

I really should of started this thread in the project section, But at the time I couldn't find it,, I found the article section, over time I found it...

The Project section is in the drop down menu on the upper left...

Maybe if you have some time, Make a How to Navigate Thread, with a Q & A section

Started taking out the headlight Buckets to re-paint and Install a new Front Lighting Wiring Harness.. more on that later.

First thing is to mark all the wiring and or photo's taken before disassembly ..yup been there done that ...

Then remove the Bulb mounting fixture

from the light bucket

The next step is to remove the upper bracket inside the bucket three screws on rotor spinnie Thing( Thick Tall # 8 machine screws, don't lose them...like Gold)

and the three on the screws on the plate...

the two on the flex plate if ya ain't cuttn the wires,,((should of.cur them..ve. got to get the unit off too))

then Remove the plate careful getting the wiring

away

Remove the bottom ( front) two screws and the rotor post and

The turn the bucket half way and Bingo that's the spot! lift it right out

""" Trick/ Tip :: The Back Of Bucket comes out First ..only one way

I try not to cut the terminals off even know am replacing with a upgraded harness

Then turn the Bucket Half way lift the back end first,,, and they pop right out

LQQK I forgot to Tape up the front to prevent scratches and mistakes,,,oops ..made none.... but If this was my first time doing this,,, I surely would be masking up the edges, and body enclosures... maybe I won't be so brave re-installing the light buckets... total time here was 3 hours

This is what usually you get back from the body shop, In my case the housing were easier for the body shop to mask then paint

Getting in a little over my head.. with the project..I hope to get all painted and re-wired before the Motor is finished... a Little everyday keeps and Opeler Happy

I've Decided that the Headlight Wiring needed to be upgraded,

It had been Repaired with heavy wire years ago, and I thought I would be nice to have new wire harness, and new micro switches,, (( Paint Dust, debrie))

I've opened up a Can of worms NOW,,, found ... Rust Gremlins .. yes, hiding behind the lighting buckets.. in the corners,,under the seam sealer,, Found a few small spots... The best way is to sand blast them Rust Gremlins if your working outdoors

(( so I grind and sand,, Rust Converter, and Epoxy Primer white.... in the light buckets

I guess I'll """ Paint It all... Epoxy White Gosh it really needs it

I guess I'll seal the Paint, Engine Bay... the belly pan area and Battery Compartment Area ... these are places the Body Shops can never do a Good job.. ,, in my case they decided to paint it black.. messy Looking job

So I'll Fresh -N- Up with epoxy Sealer Paint and Matching Yellow Urethane Top Paint make it look neat again

So Here sanding and painting,, engine bays aren't easy to sand, but after a few paint jobs and dips,, Paint Runs, Black and messy looking >>>

To control some of the over spray , I built a small tunnel out of Cardboard that is taped to the Tunnel and the garage floor,, This also stops the over spray to the Bottom and back of the car.. I hope it works,,

Taking a breather,,, all painted white,, have a few days,,before I have to add the top coat,,

It is hard to paint when the garage is so Cold,,, could only get the heat to max at 70, so I think I'll paint the next warm day,, I hope so.

This is all Epoxy White Primer,, Looks better already,, I have time now to add the top matching Yellow Top coat,, in a few days,, I hope for a warm day.... No Black clouds,,, yeah,,, knock on wood three times 🤞

I had some rust in the light bucket under the seam sealer area, cleaned out corrosion, and treated with rust converter. Repaired

Before and after photo's

I've finished with the engine bay painting Yellow, This job turned into a lot of work.

I'm no Body Shop Painter that's for sure, Got a lot of orange peel, I ran into problems setting up the China Freight Spray Gun, I think next time, buyer better sprayer gun..

.Or a Bunch of cheap Spray Guns to

switch when the gun stops spraying and spitting,clogging, and screwing up the paint job. Have to say I learned something,,, I ain't no body Man, That's for sure

Now that the engine Bay and light buckets have be restored,

I reinstalled the Chrome Bumper, and next is to install the new lighting wire harness, start getting it back together.. Lots to do... still waiting on my Motor from the machine shop. So I have time to get things back in order,,

Quote from Tlee73gt

Nice my friend you have done a much better job than I would have.

Now that were dealing with the covid do you have more time for tinkering ?

What's the latest update

I've been busy,, kinda,, everything in a timely manner,

Repainted the Hood Hinge, see the grease zerks came out ok

Epoxy primer way to Go, only have three day to add top coat before epoxy hardens

Restored the Headlight cable, removed all the flake coating, Hung cable and Lubed Cable, and Installed 3M heat shrink tubing on the outside.. Prefer to use only the Original Cable as the after market ones have problems,, I really like popping up the headlights for the Kids.

Started to install the new Lighting Harness, and in the process am wiring the whole dam car..LOL cracked wires in engine harness.

and am working on making my GT work with Throttle cable, instead of throttle rods, stay tuned Opel Fans..LOL

Quote from Tlee73gt

Very Cool !!! I am indeed liking the throttle cable and doing away with the rods that's where my gt't stiffer than I like throttle bothers me not that's it's terrible but just enough to be bothersome.

UUGGHH the wiring, son of a biscuit eater, that's never fun

Great idea with the grease fittings

Keep up the great work it all is looking fantastic

Thanks My friend for your kind words,,,Am finished with the Hood Hinge Restoration, stripped and repainted to match the GT..

some more photo's, eye candy for Opel fans, New Grease Zerks as per Rallybob,

The new Weber Cable Linkage am still working on the fabricating issues,

Here what I got, If you like it Terry, I can help you out, problem am having is locating the the throttle linkage arm I found in a parts assortment box, swap meet.

I got it working on my MGB, I don't like the bracket on the mounting bolts, I like the throttle pulled open from above, give full open throttle with my 38/38 Wever..LOL

The plate mounts on Top then goes the air filter assembly,, I made two, really need a mill machine to make a bunch, if any interest,, lever bracket hardest part, made one out of 12 gauge steel for MG. The Prototype and it's working Great after the test drive yesterday,, but it seems the top bracket will need a bit of trimming for the GT Breather hose to fit properly into the carb. filter top.. Prototype in process

Working on the linkage at throttle rod too, driver side using a Motorcycle throttle cable seems to do the trick, stay tuned for that