Sign in to follow this  
Followers 0
Mike T

My 404 Coupé Injection

72 posts in this topic

The new left rear fender is now welded on, as of February 8th, after the inner fender work was completed.

32676606722_0c1d3c7e6a_o.jpg

Share this post


Link to post
Share on other sites

Wiper frame is de-rusted and repainted in Rust-oleum and the two new wiper spindles (unique design for the 404C so I was lucky to get a pair) are remounted.  The wiper motor drive axle is the original but after flushing it with Würth HHS it was as smooth as butter.  Greased it up and mounted it back together.
32009216284_b2c6d4efc1_b.jpg

 

The cover of the AEG fuel pump was rusty and needed a good quality of hard paint because it's clamped on by a wire that uses friction and sits in the dimple of the cover.  So I bought some silver POR-15 and applied it by brush. with only 83,000 miles on the car, the electrical part of the pump is in good condition.  I will take the hydraulic part apart and regrease it. 
32037479023_8f076e8e46_b.jpg

 

The framework of the AEG/Kugelfischer pump was also very rusty but now looks better and is painted in silver POR-15 applied by brush.
32728474891_e735753116_b.jpg

1 person likes this

Share this post


Link to post
Share on other sites

Sunday I replaced the seals in the differential unit, to be specific, the input shaft of the worm drive.  These leak over time and the torque tube fills up with rear axle oil!  The mating surfaces between torque tube and rear axle unit were sealed with Hylomar Blue.  The crown wheel in bronze is in decent shape with a few pits but not worth changing at this time.  So my new worm and wheel will remain on the parts shelf.  Refilled it with Castrol R40.

32874822655_95ec016c75_b.jpg32493684220_4ca8c3b455_b.jpg

Share this post


Link to post
Share on other sites

These photos were taken Friday around 5 PM.  Major front end surgery is underway!

Front fenders are cut off!
32120355124_1b50711f38_b.jpg


Detail of cowl panel, not rusty at all inside.
32583009870_415d7b30f3_b.jpg


Inner fender panel was not in that bad of a condition, some repair was required near the bottom.
32583028680_ab1d67bb74_b.jpg


Dashboard with three rectangular holes gone and one round hole for the new - original type - wiper/washer switch!
32583050510_1ccb41891b_b.jpg


Taillights fit, good!
32149262743_945d91178c_b.jpg


Drilled out spot welds and removed outer McPherson strut tower skin.
32809840682_414ccf3d0d_b.jpg


Repair panels welded into the nose panel on both sides.
32583101790_b4bfd8590d_b.jpg


Interesting perspective!
32809868162_8da29cf85e_b.jpg

1 person likes this

Share this post


Link to post
Share on other sites

Friday afternoon I visited Coachwerks.

The new front crossmember is on, some significant repairs were needed on the driver's side inner fender and that fender is now tacked in place, with fine-tuning and possible future adjustments to follow. Next week I have to take the rubber seals down for panel alignment purposes, as well as the grille.

33192755386_99df5a9af9_c.jpg

32390252184_5ccb204b07_c.jpg

32419618613_3cafbfc8e8_c.jpg

The old front crossmember didn't look all that bad but when it was off, the bodyman in the photo above showed it to me and shook it, and it sounded just like a Maraca 1f642.png

 

They will be painting the front brake drum backing plates, the Hydrovac vacuum tank and the air inlet grille. I will repaint the brake drums myself in manifold paint.  I had them blasted at Blast-it in Victoria today and I even did the vacuum tank blasting myself!

Share this post


Link to post
Share on other sites

New paint on front brake drum backing plates, Hydrovac tank and fresh air grille.  Done by Coachwerks.  The shell didn't have anything much done to it this week as the bodyman was away.  

32555822873_0bbbf75703_b.jpg

1 person likes this

Share this post


Link to post
Share on other sites

March 24th, left front fender is welded on; other side will be done next week, and then some final welding and metal trimming will be done before paint preparation begins.

33479810602_da85d09c16_b.jpg
33595553346_529f4feb9b_b.jpg
33595505096_377cf28bd7_b.jpg

Share this post


Link to post
Share on other sites

March 31st: major welding is all done.  Next week it will be a full coating in epoxy primer, then a few weeks of blocking and priming, followed by a topcoat in Dark Blue 1057.  Exciting times!

 

33637063161_9397b3112b_b.jpg

 

32923195034_cbdb483d59_b.jpg

 

33766352335_b574371a22_b.jpg

1 person likes this

Share this post


Link to post
Share on other sites

I checked with my insurer, Hagerty, and they indicated that the car, once completed can be insured for $87,000, which is the valuation they apply to a concours condition 404C.  Right now it's insured for only $25K but that will go up to $50K after the bodyshell is painted and before it's delivered back to me.

Share this post


Link to post
Share on other sites

The first bit of paint is on, the engine compartment, trunk and underbody.  The entire car is primed with epoxy but the blocking still remains to be done.  The Dark Blue mix was based upon the paint colour chip (actual paint) from 1966 and an interpretation using modern materials of the appropriate mix.  I love it!

33517275060_312e88b003_b.jpg

In comparison, here is my friend Tim's car, which he says is about one shade too light:

33089175743_a1562c4c21_b.jpg

1 person likes this

Share this post


Link to post
Share on other sites

There is not a lot to report on the bodyshell other than it has the anti gravel undercoat on it now.

 

Friday afternoon I reassembled the struts, with new grease seals, new roller bearings for the steering swivels, new rubber boot and new upper cups.  That factory spring compressor is fantastic!

 

33657816950_5506fa72c8_b.jpg

 

33657829460_84410ef39c_b.jpg

Share this post


Link to post
Share on other sites

33483498923_dbfe15e73a_b.jpg

 

Work continues.  Wow does the blue ever look dark when the car is in the shop!  It's the same paint that you see in the engine compartment photo from a few weeks ago!

1 person likes this

Share this post


Link to post
Share on other sites

She's getting there.....

Share this post


Link to post
Share on other sites

No news visually worth recording.  It may be a few weeks before there is.  I would like to show the fully painted shell but that is not imminent.

 

In just over a week, the son of the Brampton-area Peugeot dealer that sold this car when she was new to the Victoria lawyer will come to the shop from his Ontario home to see the car for the first time in 50 years!  How cool is that?

Share this post


Link to post
Share on other sites

34635200071_248c793bdb_b.jpg

 

34727300786_2bf2892741_b.jpg

Share this post


Link to post
Share on other sites

This afternoon I decided to have a look inside the lever end of the Italian-made Nardi floor shifter that my 404C had from new.  The last two I opened up had plastic bushings that had disintegrated over time and I thought that this one had a plastic bushing too, but intact, because the lever action was perfect.

 

After removing the 4 screws below the shifter, there was some very old, dirty oil in there.  This end of the shifter cannot get any lubrication from the gearbox proper even though it's attached to it.  The other two 404 Nardi shifters I had in the past were dry in there, with just some grease on the moving parts....
35065143356_559c0380b1_b.jpg

 

After removing two circlips, the mechanism comes apart.  I could have removed the lever but decided against it because the bolt inside the mechanism is tied shut with a wire and it seemed very serene - I could clean around the lever, with it still somewhat attached.....
34260800724_5b4b77edb7_b.jpg

 

The bushing in this version of the Nardi is definitely not plastic, it's bronze or brass!  It's in great condition!
34260798604_b05da8422e_b.jpg

 

View of the bronze bushing, which when the lever is actuated, moves up and down inside the sleeve attached to the shifter rod that transmits the action to the gearbox shifting forks.
34294956183_30f65a4979_b.jpg

 

The sump has been drained and cleaned out, and the bronze bushing is again circlipsed into place.
34260794644_20a425883a_b.jpg

 

The sealing faces and threading of the little sump were carefully cleaned and then sealed with Hylomar Blue, to prevent any oil leaks.
34260792484_bed7ab80ab_b.jpg

 

Sump screw on the Nardi, accessible from inside the car, 24 mm.
34294951973_2a17751972_b.jpg

 

...and refilled with Yacco vegetable based differential oil!
34260788194_de2869248d_b.jpg

1 person likes this

Share this post


Link to post
Share on other sites

35222894031_1a88767029_b.jpg

 

New Michelin XAS tires from Longstone Tyres in the UK.  No extra charge for shipping, no tax, no duty.  Cost was £900 including 5 inner tubes.  Not cheap but it's a heritage tire design from the sixties in limited production.  Size: 165HR15, i.e. rated to 210 km/h (the car will do 170+).

Share this post


Link to post
Share on other sites

Newly powder coated wheels, new door jamb sill plates, some minor parts:

35412530872_ea6f3e4f0e_b.jpg


Rebuilt pedal assembly: 
35541993766_808f5d7e28_b.jpg


Disassembled grille:

35193834210_e41324d11b_b.jpg

1 person likes this

Share this post


Link to post
Share on other sites

You're probably thinking: "Mike, when - for criminy sake - will your 404 be painted?".  Well, I was asked to bring the grille surround back to the shop on Bastille Day to Coachwerks, as the bodyshell is virtually ready to paint.  A final fitting of the grill surround to the shell will confirm that it's ready.  Meanwhile, two of the three taillight bezels I have as well as the door handles are still at the chrome shop, as well as both bumpers, the latter for dent repair and polishing only.

 

You've read this before, but it's possible that the car will be painted in a week's time, and almost certainly by the end of July.

 

So, Peter Gallagher of Automotion, 1390 Pemberton Avenue North Vancouver, did the mounting and balancing when I was at his shop on Tuesday (11 July) morning.  When I arrived he was nearly done, but I managed to catch the last bit of work.  The wheels were "too pretty", Peter said, to hammer rim weights onto, so he used stick-on weights that will be invisible behind the large hubcaps. 

 

35831347551_b5c970837e_b.jpg

35922445936_3e498d218a_b.jpg

 

I think I will keep the two 30 year old Michelin MXL and two 28 year old XM+S 100 tires on rims, so when the car sits in the garage it can be on those tires, saving the XAS from flat-spotting during storage.

Share this post


Link to post
Share on other sites

Create an account or sign in to comment

You need to be a member in order to leave a comment

Create an account

Sign up for a new account in our community. It's easy!


Register a new account

Sign in

Already have an account? Sign in here.


Sign In Now
Sign in to follow this  
Followers 0

    Chatbox
    You don't have permission to chat.
    Load More