Exhaust Issues Continued
By · CommentsWe began from the manifold on the driver’s side (now that the manifold issue has been corrected) to the muffler, then through the x part of the frame. All the while rebuilding the hangers as we went, all is well to a point. Now with the last large piece that goes up and over the rear axle (allowing the axle to float) on its way to the resonator we again have a problem. I can only assume that the piece is bent incorrectly, the large U-shape bend is closed to much allowing the pipe to rub the rear wheel and potentially also hit the lower mount for the shock. The parts are not inter-changeable so I am confident we have everything in the right place and when we loose fit the system we did not see the problem. We are in the correct place above the axle, but in the wrong place below it.
With it being Sunday there is not much else we can do. I don’t have a pipe bender and I’m pretty sure if I try to open up that bend without one I will kink the pipe and restrict it. I will try to correct it next week and if I am not able to open it up, I will have to talk to them over at Cadillac International about a replacement. We are 16 man hours into the exhaust and still not completed.
We installed the radiator support frame, the new radiator, hoses and heater core lines along with a new thermostat. I wanted to be able to start-up without the fenders on so that we would have more room to work on any adjustments and be able to send the car out for an alignment before we close everything in.
However, that support frame is attached with only one bolt at the base and kind of floats there, it is actually the fenders and splash panels that stabilize it and now I am worried about trying to start-up with it not secured, there is not a lot of clearance between the radiator and cooling fan. I decided to fabricate two temporary supports that run from the support frame to the front of the frame where the bumper brackets mount.…. Problem solved and we are good to go now.
Now another problem, with the radiator up, we can see that the tranny cooling lines are in the wrong place. They will have to be pulled out re-routed and re-installed correctly so that they will meet up with the front set that goes through the radiator support frame. Once that is done, we will install 2 new hoses to connect the two original metal tubes, and will fabricate them in the shop to close that part of the system. The only things keeping us from start-up now are the completion of the exhaust system and installation of the distributor and coil (we are waiting on parts for those).
Exhaust Issues
By · CommentsWe began assembly and installation down the passenger side of the vehicle now that we have the flanges. We took a considerable amount of time making sure everything was just perfect. As we got to every hanger, we pulled it down cleaned the metal parts and installed new rubber that we custom made in the shop using the old ones as patterns. The only difference between the originals and ours is they were riveted together and instead are now bolted. The system ordered from Cadillac International appears to be of very high quality and every junction lines up at a hanger just as it is supposed to. The passenger side is now complete and rock solid. Amazing factoid.…it took 9 muffler clamps to assemble just that one side, from the manifold to the muffler, to the resonator and then out to the tailpipe.
Now for the driver’s side, the real fun begins.….. Here we have not only the exhaust flange but the heat control diverter valve, plus 2 gaskets. Well it seems the new flanges are much thicker than the originals and now the manifold studs are not long enough to get the nuts to grab. No way around it, the studs have to come out and be replaced.
The first one came out easy as pie and we then spent an hour trying to remove the second one (Murphy’s Law strikes again!). We finally decided the only way to get it out was going to be to remove the manifold (and ruin the new gaskets), I was sure we were going to break it off and have to send the manifold out to be drilled and tapped. Once on the bench in a vise and with a pipe wrench it finally gave way and came out. New studs are in and the manifold is re-installed and finally we are ready to go. Time to call it a day.
Sorry For The Delay
By · CommentsWell when time permitted over the last 2 weeks, when not fighting our computer virus, we have been busy assembling the external engine parts. We now have installed the power steering pump, water pump, oil filter canister, fuel pump, oil switch and coolant temperature sensor. All are now wired and plumbed correctly.
The generator and starter are in and connected along with the fan belts. We also installed the carburetor, which is back from a complete re-build and put in the fuel line from the fuel pump to the carb. We are almost ready to go.
We also spent much time installing the exhaust manifolds. When we opened the exhaust system boxes we realized that no flanges were included to attach to the manifolds, we had to get a pair of those. It took better than an hour to route the tranny cooling lines up through to where the radiator will be.
Computer Problems.….
By · CommentsSorry for the delay in updating.…We are struggling with a computer virus that limits our ability to be on-line. We have much to say, but unable to get it in right now…
See ya soon!
We Are Moving Forward
By · Comments Spent most of the day Sunday and today tweaking the engine and tranny, setting the mounts and making sure everything was aligned. It took quite some time, but finally I was happy with it, everything looks and seems square, we installed the exhaust manifolds, water pump and fan and then spent hours trying to loose fit the new exhaust system.
What a jig saw puzzle that is, a box full of pre-bent pipe, two mufflers and two resonators. I think we finally have the correct layout and we have it tacked in with the muffler clamps and will secure it once and for all when I am confident that it is perfect. Now comes the detail work, I’ll spend the rest of the week mounting the oil filter, power steering pump, fuel filter, fuel pump, generator and starter. We are getting close to the day that we can finally roll her over and hear her purr…
After much debate, we finally sent the Rochester 4 barrel carb out to a local guy who likes to work on this kind of stuff. I’m sure it needs a very good cleaning and after everything else we have done a full re-build won’t hurt, when it is ready later in the week, we’ll get that installed too.……
Happy Halloween
By · Comments

Axle Is In.…Ready To Roll
By · CommentsAxle is back in, and man was that chunk of iron heavy! When we took it out, we had pulled the differential and the axle shafts out and only had to haul out the tube.
This time, we assembled it all on the bench, differential was back in, axle shafts with new bearings and seals were all installed. Man that sucker must of weighed in at 200 – 300 lbs. I swear you could use that thing in a dump truck.…. Anyway, with 2 of us it was easier than trying to assemble it under the car. Once we had it aligned with the lower control arms it was easy, inserted the springs in their seats and used a floor jack under the differential to compress them until we could mate the ball joint mounted on the upper yoke with the flange on the axle. All in all, the whole process took less than an hour.
The rain stopped, so I borrowed my brother’s pickup and we were off to pickup the motor at the shop. There it was, strapped to a pallet and shrink wrapped just waiting for me.… Couple minutes with the forklift and we were on our way back to the shop. Original plans were to just drop it off, but with some time left and nowhere to go we decided to just mate it to the transmission and drop it in the car. It really
was a long time ago that we took it apart, and our first attempt, we forgot to put the spacers between the thrust plate and the flywheel, so we ended up having to take it apart again and put it back together the right way. Once that was done, 20 minutes later and both the engine and tranny were back in the car. Enough for one day, we’ll be back at it on Sunday.
Yoke’s On Me
By · CommentsThe rear upper control yoke is back from the shop after having new bushings pressed in. Got it installed on the car today and we are ready to put the axle back in tomorrow when I will have a helper. Things are moving a little slow, trying to get organized again, being away for 2 1/2 weeks, I ind of forgot where I was going and where I was when I left. Spending a lot of time just trying to organize my thoughts and the shop too! As soon as I can arrange to borrow a pickup truck, next project will be to pickup the motor from the shop and get started putting that beast back in…
We’re Back From The North
By · CommentsWell, we made it back, docking in Boston on Friday. We had a wonderful trip, very nice weather and saw some great sights, even a little snow. After a couple days of cleaning up the mess in the office and reducing the pile of paperwork on my desk, we are ready to move forward. A few more meetings with the accountants and lawyers and we will have much more free time to devote to our favorite project.
We now have the seat belts installed, the transmission painted and ready to install and today began to install the rear axle back in the car.
Honestly, it was not a very productive day, it began with a one hour search for the lower control arms. It seems that in the chaos prior to my leaving, I had taken them to NAPA to have the new bushings pressed in and somehow forgot to pick them up, while away two of my employee’s cleaned up the garage, doing me a favor, and now I had no clue where they were or where to look. Luckily after an hour I took a shot with NAPA and was very relieved to find them there. The two missing
bushings for the upper control yoke arrived while I was gone and now I am waiting for those to be pressed in.
We managed to get the axle under the car, connected the lower control arms and will finish when the upper yoke is ready probably tomorrow. The hard work is done, once the yoke is here, we will install the new rear ball joint, compress the springs and bolt it all down tight. Weather here has not been great, but I hope to pick the motor up from the shop this week and we may get it back in the car this weekend.
Cruising — Again…
By · CommentsWish you all a happy and safe Columbus Day Weekend… Mary Lee and I arrived in Boston last night and are taking a shuttle over to Black Falcon Pier at Noon, where we will board the NCL Spirit, look up a Canadian friend who will be joining us and set sail at 5:00PM. We will be making ports in both the US and Canada, including Bar Harbor, Prince Edward Island, Nova Scotia, New Brunswick, La Baie, Sept-Isles, Quebec City, Portland, and also cruising the Saguenay Fjord and Saint Lawrence Seaway before returning to Boston on October 23rd. The foliage should be spectacular, at or near peak, and we may even see some early snow while in the northern reaches
We’ll be back to working on the “Gray Lady” after we return, hope to keep things moving and look forward to seeing you then.…
