Making templates

Making templates for front main sill. This is 16 gauge sheet metal; the middle sill and outer rocker are 18/20 type gauge metal. 

The fun stuff!

Cleaning and cutting bad metal;

Cutting bad metal

Started cutting bad metal out of rockers....fun work!

Passenger side:

Driver side:

More rear ended disassembly

Trailing arms off. 

Straps off. 

Inspecting differential. Seal its been leaking for a long time.

Rear off!

Labor intensive but fun!

Front suspension off!

It's finally off the car!  Now time to refinish and change vital parts. 

Driver side:

Passenger side:

Washer on the frame side. 

Spring pans off

Today I tackled the spring removal. I ordered a 3' long 3/8"-12 ACME and cut it to 12" long with my Dremel cutting wheel. Replaced the 2 front bolts and left rear bolt with the rods. Of course I'm new to this so I placed a big vise just in case....didn't want any surprises! Very controlled. You can probably remove the pan with only two rods but better safe than sorry. 

Bought theses type long nuts to be used as spacers. 

On top of the spring pan there are three bolts with washer and nut on the bottom. One washer and nut on top right front hole to hold the stabilizer bar. 

Trailing arms

Softening up the trailing arm bolts. I've been hitting them with PB Blaster for a couple days now and purchases another 22 mm socket. This morning I was able to move the nuts in and out without too much effort. Ready for disassembly. 

I also removed the rear stabilizer bar. 

Rear rotors

I also removed the rear rotors....they were baked in rust...took me two days soaking the area with PB Blaster and they came off!!!

Differential oil

This morning I drained the oil from the diff; I was surprised to find really clean oil! I found a magnetic drain plug that had just a slight gray type residue...no doubt minuscule metal shavings attracted by the magnet...cleaned it and reinstalled it. Refilling it with Redline 75W90 NS. 

My differential feels really good...tight without any play. Feels direct and connected....I think I'm just going to clean it up, paint it and reisntall.  Certainly it's coming down while I restore the body. There is a leak and I'm not sure if it's coming from the drain plug or front seal...there must be a seal....right? Need to research. I'm wondering if I can service it without a full blowned brake down. 

Topped off with new fluid. 

Up in the air

So I finally got the Berlina up in the air....20" up in the air!  I have to take care of my 50 years old back!

My body cart

Installing the front legs of my body cart on the Berlina. It will seat 16" up in the air for easier access to the rocker panel and froor repairs coming up.