Yak about stuff. Just stuff.
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April 2012

Cut cylinder 2 & 4 flanges off the exhaust to be able to fit the heater boxes and align the tail pipes to the apron cut outs...

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Well... These headers were off target quite a bit... :?

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May 2012

Cylinder #1 connecting tube was ok - no correction was required.
Cylinder #2 header pipe partly cut and alignment corrected...

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Cylinder #3 connecting tube completely cut out and correctly welded to the muffler.
Cylinder #4 header pipe partly cut and alignment corrected...

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New flanges and header pipes fixated. Ready for welding...

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My welding skills are poor especially when it comes to stainless steel.
So I asked a buddy who is a professional welder to help me out.

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Welding done, exhaust mounted - it fit quite well...

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After a few warm up and cool down cycles no leaks and no significant distortions were detected.
So this accursed "need like a hole in the head" exhaust issue was finally solved...

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Wow, that's a bunch of work for a finished exhaust that looked as good as that one did. Poor form on their part not to provide any support for what they sold you.
schwim wrote: Poor form on their part not to provide any support for what they sold you.
Well, I suspect most of their exhausts were poorly welded and they knew about it...
Even the tailpipes don't run horizontal parallel either. :(


June 2012

During the first few roads tests fuel pump issues emerged. :x

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During summer 2011 I rebuilt the fuel pump using one of these infamous crappy aftermarket kits. :roll:
Here are the original parts. That 42 years old diaphragm didn't inspire much confidence...

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And then we have the replacement diaphragm. Its quality was quite questionable.
I was uneasy about it but decided to give it a try...

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Well... The misgivings were confirmed - that pump leaked badly. :evil:
There was no chance to get the diaphragm correctly installed and the pump housing sealed the same time.

I ended up with a home made rebuild kit and cut out the diaphragm using special material (called "Membrantuch" in German).
Check out my super special high-end pump pre-loader (that little log of wood with the wood screws). :D

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The parts of the dismountable diaphragm assembly:
- machined stainless steel pull rod
- modified original diaphragm retainers
- stronger pressure spring (taken from the aftermarket kit)
- cut out diaphragms and seal ring

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Unfortunately I have no close up of the assembled diaphragm. :?
A least here's a blow-up from a pic taken during the final gathering of spare parts from the hoard...

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September 2012

The once more rebuilt fuel pump with the home made diaphragm assembly ran flawlessly during the rest of the driving season. 8-)
But another issue spoiled the fun: leaking oil from crank pulley! :(

Due to the poor oil return thread of that shiny after market pulley oil was spilled all over the engine bay and deck lid. :x
So that crap had to go!

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I ended up with another seemingly better quality aftermarket pulley and there has been no leak to this day.
However most likely I'll change back to a stock pulley in the near future. I'm fed up with today's aftermarket crap.

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FWIW a few pics of various crank pulley oil return threads...

Aftermarket 2011 (violently leaking)
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Aftermarket 1989 (moderately leaking)
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Aftermarket 2012 (not leaking)
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Stock 1970 (not leaking)
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so what brand pulley is the aftermarket non leaker?
just because it's a bad idea, doesn't mean it wont be a good time
The etching reads EMPI... :D
wtf empi made something that works? :shock:
just because it's a bad idea, doesn't mean it wont be a good time
I imagine it might have something to do with the era of the EMPI piece.

I found a lot of variance in the "stock" pullies that used to come through the engine shop I worked at. It was hard to find a true original as there was just a glut of stock repros that were of terrible quality. My boss used to find the good ones and keep them in a box for future builds.
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