TeamCapri

General => Build Threads => Topic started by: theastronaut on October 06, 2021, 07:31:06 PM

Title: '92 Mild Widebody Build
Post by: theastronaut on October 06, 2021, 07:31:06 PM
I'm new to the forum but have been in the Capri groups on Facebook for a few years. This is my tenth Capri and was the most solid base to build from.  It's a 100% rust free South Carolina car that had been advertised on craigslist for $1200, then sold and a few months later advertised on OfferUp for $1000.  I saved it to keep track of it and about a month later the price dropped to $550 so I sent a message and asked a few questions but we weren't able to work out a time to meet up and check it over.  About two weeks later he asked if I was still interested and had dropped the price to $450 so I loaded up the trailer and picked it up. 

(https://i.imgur.com/Ew86I7jh.png)

(https://i.imgur.com/QBG4dnMh.jpg)

(https://i.imgur.com/z2Kun3Yh.jpg)


It was originally white but had a really poor repaint.  The top was in bad shape, radio wiring was a mess, it had the wrong battery, the lower rad hose was a weird flexible metal hose, the windshield was busted, and it had broken it's third alternator belt (the reason the PO was selling it) but hadn't been overheated.  It started and ran well though, only had 129K, and the body was solid so I figured at worst it would be a good big nose B6d engine donor for one of my Festivas, and part the rest out. 

(https://i.imgur.com/Raxk0FXh.jpg)

(https://i.imgur.com/AJeknf4h.jpg)

(https://i.imgur.com/TpNA5Mfh.jpg)

(https://i.imgur.com/hnDRx6ah.jpg)

(https://i.imgur.com/pu5Pjxmh.jpg)

(https://i.imgur.com/cB83GcJh.jpg)

(https://i.imgur.com/JS47CGrh.jpg)

(https://i.imgur.com/6Wh1EQsh.jpg)
Title: Re: '92 Mild Widebody Build
Post by: theastronaut on October 06, 2021, 07:58:00 PM
After getting it home and going over it more closely I decided to make it a daily driver so I ordered a new top, swapped on a set of Tokico struts with H&R springs from a parts car, fixed the belt and rad hose, pulled out most of the interior, and started driving it. 


'92 parts car that I bought last year. It was parked in a field for 10-12 years and is pretty rotted- even the windshield frame has rust holes across the top.  It had a bunch of cool parts like the struts/springs, clear marker lights, '94 XR2 spoiler, K&N filter, and a powdercoated valve cover.  They said they parked it when it started knocking but after getting it running it seems to just have lifter tick.  Not a bad find for $150...

(https://i.imgur.com/YtvtLhih.jpg)

(https://i.imgur.com/Ik4lkBnh.jpg)

(https://i.imgur.com/k31Ule3h.jpg)


My plans for the car were to pull out anything unnecessary to drop as much weight as possible.  The interior was trashed so almost all of it ended up in the dumpster.  I cleaned and painted the floor to match the dash color, removed the mess of stereo wiring, detailed the dash, console, step plates, etc, and bought/mounted a used Sparco race seat from a friend.  I had to swap in a headlight module (it was missing) and both headlight motors from a parts car to make the headlight doors work again.

(https://i.imgur.com/L7rRnaUh.jpg)

(https://i.imgur.com/G9vjas9h.jpg)


The heater floor duct was routed to the back floor so I cut it off so heat would be directed to the front floor instead.

(https://i.imgur.com/XhKJgVQh.jpg)

(https://i.imgur.com/Y98CZOeh.jpg)


Indoor/outdoor grip tape to replace the pedal pads.

(https://i.imgur.com/EPvZRBmh.jpg)


Sparco seat... I haven't decided if I'm going to keep it and order a new cover for it, or find a matching pair of seats to swap in instead. I mounted it using a set of universal side mount brackets and the sliders from the stock seats. 

(https://i.imgur.com/A5c5YhUh.jpg)


New top installed.

(https://i.imgur.com/HvRFHGGh.jpg)


At this point I had the rad hose fixed, new wider alternator belt on, battery swapped out for the correct size and bolted in using hold down parts from the white parts car, and a bunch of other small issues sorted out.  It looked much better slightly lowered with the new top, but still pretty ugly.  A friend of mine wanted the steel wheels for his 323 so I began looking for wheels. I got it registered and insured and started driving it back and forth to work.

(https://i.imgur.com/UV5kEezh.jpg)

(https://i.imgur.com/QxCXFSwh.jpg)
Title: Re: '92 Mild Widebody Build
Post by: theastronaut on October 06, 2021, 08:17:27 PM
My original plans were to build more of a stance/slammed look so I bought 15x9 -15 wheels and found a good deal on 205/50 tires. 

(https://i.imgur.com/dy7pgxHh.jpg)


They didn't come close to fitting, but that's what camber and cutting is for...  2nd/3rd pics are with a few degrees of camber dialed in and the fender rolled/pulled out as much as possible.

(https://i.imgur.com/KvV3LEch.jpg)

(https://i.imgur.com/vnKRKu1h.jpg)

(https://i.imgur.com/f5DmZZhh.jpg)


Rear before/after cutting the inner wheel well loose, using a hydraulic ram to push the quarter panel out, and rolling the lip flat. The quarter is noticeably more curvy or flared compared to the stock quarter in the last pic. 

(https://i.imgur.com/vstZn4jh.jpg)

(https://i.imgur.com/DPC93xFh.jpg)

(https://i.imgur.com/y05XB3Ch.jpg)

(https://i.imgur.com/JJWwusAh.jpg)


The gap was filled in with a strip of sheetmetal using rosette welds to attach it.  I later sealed it with primer and seam sealer. 

(https://i.imgur.com/ICYHRVth.jpg)


The quarters kinked above the wheel opening from pushing them out so much so I used a hammer and dolly to reshape the low spot.

(https://i.imgur.com/17JIzMIh.jpg)

(https://i.imgur.com/sCvjk8dh.jpg)


Process of sanding to find the high/low spots, then working the panel until the shape was corrected.

(https://i.imgur.com/b3x12THh.jpg)


Finished up with a thin skim coat of filler.

(https://i.imgur.com/ERz6DVIh.jpg)


Difference between the stock side and the widened side.

(https://i.imgur.com/Yw73y1Eh.jpg)


Went ahead and started bodywork on the rest of the car.

(https://i.imgur.com/UdJZvh8h.jpg)


Title: Re: '92 Mild Widebody Build
Post by: theastronaut on October 06, 2021, 08:26:08 PM
Test fitting with the tires mounted. 

(https://i.imgur.com/qWUoNeph.jpg)

(https://i.imgur.com/XZW6M2Gh.jpg)

(https://i.imgur.com/J00U37fh.jpg)

(https://i.imgur.com/k4lBsVph.jpg)


Title: Re: '92 Mild Widebody Build
Post by: greywolf27030 on October 07, 2021, 08:24:35 AM
WOW....welcome to the forum. You're going to town on that thing. I'm glad to see owners who are wanting to do things to personalize their Capri's. I'm going to have to start shopping in SC. I'm in NC and the cheapest Capri I've seen up here is a non running N/A with 188K for $500/ Where are you located in SC?
Title: Re: '92 Mild Widebody Build
Post by: theastronaut on October 07, 2021, 05:33:46 PM
WOW....welcome to the forum. You're going to town on that thing. I'm glad to see owners who are wanting to do things to personalize their Capri's. I'm going to have to start shopping in SC. I'm in NC and the cheapest Capri I've seen up here is a non running N/A with 188K for $500/ Where are you located in SC?

This is John Glenn in Anderson  ;D
Title: Re: '92 Mild Widebody Build
Post by: theastronaut on October 07, 2021, 06:01:48 PM
Before I got that deep into bodywork, I had been driving it daily which uncovered a few issues.  I had it out in a rain storm and the passenger floor filled up very quickly.  I found the leak after some poking around- the extra wiper hole for rhd cars that only had tape to seal it from the factory.  The tape was gone so it was dumping water straight into the heater box under the dash... really great design  ::)  That lead to pulling the cowl and fan motor.   I fixed it with more tape, but used 3M foil tape which should be much more durable. 

(https://i.imgur.com/3e7XeXbh.jpg)

(https://i.imgur.com/742HyjEh.jpg)

(https://i.imgur.com/1tGKJBnh.jpg)

(https://i.imgur.com/lZVl6Irh.jpg)

(https://i.imgur.com/RBDd77Xh.jpg)


The windshield was terrible- cracked plus badly scratched and pitted.  Driving at night was rough. 

(https://i.imgur.com/bQDIdhUh.jpg)


The water pump gave up after about 400 miles, so I tore it apart and redid the w/p, timing belt, cam/crank seals, and refinished the valve cover.

(https://i.imgur.com/KbytXmvh.jpg)

(https://i.imgur.com/w7jnD4Vh.jpg)

(https://i.imgur.com/u4JssD5h.jpg)

(https://i.imgur.com/UrJLTmyh.jpg)


With the mechanical work out of the way, I spent more time finishing the rough bodywork to prep it for high build primer.   I welded up the holes for the emblems, antennae, passenger side door lock, third brake light, and spoiler.  The white primer is SPI Epoxy to seal the metal and bodywork.  I bought enough to use it to seal up the areas that had bare metal or filler, and to mix with reducer and use a sealer coat after the 2k high build was sanded. 

(https://i.imgur.com/YoTCyeph.jpg)

(https://i.imgur.com/iguTFwIh.jpg)

(https://i.imgur.com/NYTLjimh.jpg)

(https://i.imgur.com/35klDGMh.jpg)


With everything roughed in I sanded the whole car with 180 to prep for 2k high build primer from Southern Polyurethanes Inc. 

 (https://i.imgur.com/FvLKvJ1h.jpg)

(https://i.imgur.com/arLZH5nh.jpg)

(https://i.imgur.com/x9kRe8zh.jpg)

(https://i.imgur.com/BgX73VNh.jpg)


Starting to block the panels out with 220/400 grit via wetsanding. I used dry guide coat to make sure all of the 220 grit scratches were sanded out. 

(https://i.imgur.com/vJiOYT9h.jpg)

(https://i.imgur.com/4Kft3Ekh.jpg)

(https://i.imgur.com/2fXfbuoh.jpg)

(https://i.imgur.com/RS8Shjrh.jpg)

(https://i.imgur.com/k7Y5ZIoh.jpg)


I later on pulled the top cover and trunk lid so I could clean and prep the jambs for paint. 

(https://i.imgur.com/qvSOfxzh.jpg)

(https://i.imgur.com/IpsEQwkh.jpg)


Cleaned out, painted, and hung new lights in the stall it had been stored in.

(https://i.imgur.com/Uvmoto1h.jpg)

(https://i.imgur.com/54CireQh.jpg)


Title: Re: '92 Mild Widebody Build
Post by: EShepherd on October 08, 2021, 05:43:27 AM
Dude, this is AMAZING!

Once mines running, can I pay you to do my bodywork? I don't have this kind of talent.
Title: Re: '92 Mild Widebody Build
Post by: greywolf27030 on October 08, 2021, 08:34:53 AM
WOW....welcome to the forum. You're going to town on that thing. I'm glad to see owners who are wanting to do things to personalize their Capri's. I'm going to have to start shopping in SC. I'm in NC and the cheapest Capri I've seen up here is a non running N/A with 188K for $500/ Where are you located in SC?

This is John Glenn in Anderson  ;D

hahahahaha
Title: Re: '92 Mild Widebody Build
Post by: theastronaut on October 10, 2021, 12:15:11 AM
Dude, this is AMAZING!

Once mines running, can I pay you to do my bodywork? I don't have this kind of talent.

Thanks!  Nah, this is one of my last body/paint jobs.  I mainly wanted to paint it to gain experience with the sealer and clear I used before I use it on customer work at our resto shop. 
Title: Re: '92 Mild Widebody Build
Post by: greywolf27030 on October 10, 2021, 08:53:08 AM
Nice paint booth.
Title: Re: '92 Mild Widebody Build
Post by: theastronaut on October 10, 2021, 01:14:32 PM
Nice paint booth.

It's just a prep stall, not really a booth. There's a bigger stall with filters in/out that we use as a booth but it's being used as storage for now. 

Title: Re: '92 Mild Widebody Build
Post by: theastronaut on October 10, 2021, 01:16:45 PM
Once every square inch was blocked with 220 and 400 I washed it down with a red scuff pad and dawn dish detergent to make sure it was super clean, along with cleaning the stall really well.  I masked it then shot sealer and base one day, then let it dry overnight and nibbed any trash before spraying the last coat of base and three coats of clear.  I used Southern Polyurethanes Inc. Euro Clear mixed 4:1:2 and their Pure White base.  It was back in the summer when I shot the paint so I worked early in the mornings so the clear wouldn't set up as fast.  I bought the paint last winter thinking it would still be cooler when I painted it; I really needed slow activator so the clear would have time to flow out better than it did. 

(https://i.imgur.com/Mv9aBznh.jpg)

(https://i.imgur.com/bUtT7jOh.jpg?1)

(https://i.imgur.com/aZKxje9h.jpg)

(https://i.imgur.com/ahkxX9Dh.jpg)

(https://i.imgur.com/dCdaN2Bh.jpg)

(https://i.imgur.com/wBPI9LCh.jpg)


After a couple days I began reassembly. All of the black plastic was prepped and shot with SEM Trim Black to restore a consistent finish on all of the peices.  The tail lights were buffed.  I pulled a crack-free windshield from a parts car and spent 5-6 hours polishing out all of the wiper scratches.  I picked out the best windshield trim and outer door glass weatherstripping from my four parts cars then refinished them. 

(https://i.imgur.com/Bd9zZZFh.jpg)

(https://i.imgur.com/c3iS7K8h.jpg)

(https://i.imgur.com/h2bu4tqh.jpg)

(https://i.imgur.com/Y75u0fMh.jpg)

(https://i.imgur.com/pnSMlcdh.jpg)

(https://i.imgur.com/c6ekMCkh.jpg)

(https://i.imgur.com/rNojxLzh.jpg)

(https://i.imgur.com/1knGsRzh.jpg)

(https://i.imgur.com/q8jpBbdh.jpg)

(https://i.imgur.com/TMdEQFLh.jpg)


Started wetsanding and buffing the paint to remove the orange peel and trash.

(https://i.imgur.com/0fIfkAgh.jpg)

(https://i.imgur.com/eKTkX7lh.jpg)


I use a sharpie marker to mark each imperfection and also the edges and body lines so I can easily monitor how much clear I'm sanding off so I only take the minimum amount off to level the paint.  Pretty much zero risk of sanding through the clear this way.  I started with 1000 grit, then 1500, 2000, and 2500 before buffing with a wool pad then polishing with a foam pad and swirl remover.

(https://i.imgur.com/ylcQJydh.jpg)

(https://i.imgur.com/rVSMSnRh.jpg)

(https://i.imgur.com/TIin04Ph.jpg)

(https://i.imgur.com/hHYptxQh.jpg)
Title: Re: '92 Mild Widebody Build
Post by: EShepherd on October 10, 2021, 06:09:49 PM
Wow man, this is some seriously impressive work. I really can't wait to see the final result. Those headlights are cool lookin', too.

What do you plan on doing with the rubber molding stuff that goes along the sides of the car? Mine is falling off and nasty looking....I bet you've got some neat way to restore it that I'd love to steal :P
Title: Re: '92 Mild Widebody Build
Post by: theastronaut on October 10, 2021, 09:57:55 PM
Wow man, this is some seriously impressive work. I really can't wait to see the final result. Those headlights are cool lookin', too.

What do you plan on doing with the rubber molding stuff that goes along the sides of the car? Mine is falling off and nasty looking....I bet you've got some neat way to restore it that I'd love to steal :P

Thanks!  The headlights are the only LED's I could find that have a usable beam pattern and a low beam cut off so they don't blind oncoming traffic without costing $500+.   One of the reasons I wanted to build a Capri was the sealed beams- lots of options for seeing better at night.  I drive 15 miles every night, 10 of those are rural and deer are everywhere. 

I'm leaving the trim off, the bumpers will be all white to match.  SEM dye works really well for restoring the side trim and they have a lot of grays to choose from.  They also have red for the insert. 


Low beam (needs to be adjusted lower).   Notice that the pic was taken through the windshield- no hazy scratches! 

(https://i.imgur.com/e0C77BSh.jpg)


High beam.

(https://i.imgur.com/7aSONI9h.jpg)
Title: Re: '92 Mild Widebody Build
Post by: greywolf27030 on October 11, 2021, 09:24:33 AM
Excellent work, you definitely get an A+. What is the info on the lights? I got Hella conversions for my '93 but those look like they might be getter. Definitely cool and I would think draw less amperage.
Title: Re: '92 Mild Widebody Build
Post by: theastronaut on October 11, 2021, 09:55:12 AM
They're way better than Hella H4 conversion.  I bought Hellas for dad's S10 years ago and while they're better than sealed beams they're pretty poor since the reflector area is really limited on 4x6 headlights.  The LEDs are really good on low beam.  High beam is decent but doesn't have as much distance lighting as I want so I'm planning on adding driving lights to get more light farther down the road. 


https://www.amazon.com/Z-OFFROAD-Headlights-Rectangular-Freightliner-Oldsmobile/dp/B07ZH6L5PS?ref_=ast_sto_dp&th=1&psc=1
Title: Re: '92 Mild Widebody Build
Post by: theastronaut on October 11, 2021, 12:34:31 PM
I bought a Momo Futura in the rare darker gunmetal color for the build awhile back but never could find a hub adapter that fit correctly, so I made my own.  I pressed out the steel insert from the cast steering wheel so I could weld it into the adapter I machined down from a Honda Odyssey hub.  The Honda hub's ID was a perfect press fit for the steel insert from the capri wheel. 

(https://i.imgur.com/s8jP9TMh.jpg)

(https://i.imgur.com/UmsVS9ph.jpg)

(https://i.imgur.com/pO27na6h.jpg)

(https://i.imgur.com/VlHDGdhh.jpg)

(https://i.imgur.com/2SmYk9Ph.jpg)

(https://i.imgur.com/LnDFW4ih.jpg)



After parting off the flange I turned the OD down to fit an outer trim cover from a cheap Miata hub adapter I got from ebay.  I still need to make a larger cover to hide the big opening in the column trim around the clock spring.

(https://i.imgur.com/4l70jlXh.jpg)

(https://i.imgur.com/CP6D6y0h.jpg)

(https://i.imgur.com/xFaf2VLh.jpg)


After welding the insert in.  I need to buy a 1.5" spacer to get the wheel away from the stalks and closer to the seat.  I also want to modify the shifter to make the knob ~1.25" closer to the seat, and dent the floor under the pedals to drop my feet about an inch lower. 

(https://i.imgur.com/sgBbm5mh.jpg)
Title: Re: '92 Mild Widebody Build
Post by: theastronaut on October 11, 2021, 09:22:53 PM
I got the car out of the shop for the first time since January about a month ago.  The shop is right beside a high school so I drove it around their parking lot to make sure it was still running good.  Notice that it's sitting lower in the rear...  with the extra weight I've pulled out the car wasn't as low as I wanted it even with the H&R drop springs.  The bumpers weigh a good bit and reinstalling them would drop it slightly, but I'm not planning on reusing them... more on that later. 

(https://i.imgur.com/J1t58njh.jpg)


I cut out the one section of the progressive coils and made a limiting strap from seat belt material to keep the spring from getting loose in the spring pockets.  This also reduces body roll since the spring isn't pushing the inside wheel down/body up in corners. 

(https://i.imgur.com/i4qocfih.jpg)

(https://i.imgur.com/fueeMH6h.jpg)


Before cutting/no limiting strap.

(https://i.imgur.com/M18p1DAh.jpg)


After cutting with limiting strap.
(https://i.imgur.com/GRmhkSHh.jpg)


So the rear was noticeably lower but still not as low as I wanted, and it now had almost no bump travel.  Back to the drawing board. 

(https://i.imgur.com/n0IzY3Jh.jpg)
Title: Re: '92 Mild Widebody Build
Post by: theastronaut on October 11, 2021, 09:49:42 PM
On my Festivas I've used MK2/3 Golf/Jetta coilovers on the front to drop the car and make it handle better.  The Capri knuckle interchanges with Festiva knuckles so I bought a set to try out knowing I could use at least the fronts.  Festivas can't use the rear VW coilovers so if they did end up working on the Capri then the Festiva community's leftover rear coilovers will finally have a purpose.

(https://i.imgur.com/QwYEgoRh.jpg?1)


After pulling the cartridge out of the VW coilover.  The shock insert is from a Rabbit front strut, we use those to replace the shock inserts if we blow a front coilover.  They're a bit under-damped on the front of a Festiva so I'm hoping its about right for the rear of the Capri.

(https://i.imgur.com/j6FBC7qh.jpg)


Carefully cutting into a Capri strut to drain the oil.

(https://i.imgur.com/67FqrZ3h.jpg)


Gland nut modified on the lathe from a squared recess to a tapered recess to center the shock insert in the housing.

(https://i.imgur.com/YkSmEwWh.jpg)


First attempt- Shortened coilover housing, shortened Capri housing.

(https://i.imgur.com/ZkUgzwPh.jpg)

(https://i.imgur.com/hpaCWBFh.jpg)


Mocked up... I cut the housing too short, this is fully extended.  Measure twice, cut once?   ::)

(https://i.imgur.com/S5PFPK2h.jpg)

(https://i.imgur.com/qywxcnxh.jpg)


Plenty of compression travel, the tire is against the inner fenderwell.  I'll either pull another strut off a parts car to chop longer, or get a leftover coilover from a Festiva friend and chop the coilover tube longer, and add a spacer under the insert. 

(https://i.imgur.com/kF798kZh.jpg)

(https://i.imgur.com/52fa9NKh.jpg)



Title: Re: '92 Mild Widebody Build
Post by: theastronaut on October 11, 2021, 10:41:57 PM
Bumper situation- I've hated the stock bumpers, both the 91-93 and the '94 version the whole time I've had Capris.  They're just too big and have way too much overhang. The proportions of the Clubsprint bumpers are way better but I'm not crazy about those either, they have a cheap "kit car" look. I had an idea to swap on bumpers from a first gen Eclipse but finding the bumpers I wanted didn't seem possible in the time frame I wanted to finish the car by.  So I started prepping the stock bumpers to use temporarily. 

Stripped and shot with three coats of SPI epoxy. I used red because it was just out of date, so I didn't want to use it on the really important shop projects. I used 120 on a DA to strip them which was probably too harsh but there's no risk of the epoxy not sticking this way.  The nice thing about SPI epoxy is that is stays flexible so it won't crack on plastic bumpers if they flex, and it builds thick enough to fill in imperfections almost as good as a high build. 

(https://i.imgur.com/O2EizSyh.jpg)

(https://i.imgur.com/FcEzo8nh.jpg)


I roughed up the tag bracket holes so filler would have more surface area to grab onto.

(https://i.imgur.com/qznaTqRh.jpg)


Block sanding the texture out with 150 grit.

(https://i.imgur.com/PsxAhAFh.jpg)


Fully sanded smooth, three more light coats to seal over the filler and have enough material to wetsand with 400. 

(https://i.imgur.com/IbQrkRxh.jpg)

(https://i.imgur.com/11KtuL0h.jpg)


A Festiva friend in Indiana found a rough but usable Eclipse front bumper in a local junkyard and it worked out to "Festiva Train" it from Indiana to Illinois to Kentucky, then to the Festiva Madness show in NC where I was able to pick it up a couple weekends ago.  I cut the upper lip off to get it to tuck under the header panel and zip tied it in place to take pics.  The fit is pretty amazing as is.  I'll have to make the diagonal cut at the fender edge, and possibly cut and reposition the wheel opening to make it match up with the diameter of the Capri wheel opening.   The overall shape and size is what I was hoping for- it sticks out from the header panel half as much as the stock bumper as-is and I can do some slight trimming and tuck it in even further.  I'll probably go ahead and paint/install the stock bumpers for now so I can be driving it soon (maybe next week?) and use a parts car to fit/prep the Eclipse bumper.  I'll build a lightweight inner bumper frame out of 1/16" plate for the mounting plates, and 1/2" round tubing rolled to the bumper's shape.   I'm planning on filling in the vertical indention for a smoother look. 

(https://i.imgur.com/0EEwU8Gh.jpg)

(https://i.imgur.com/uouy0Ahh.jpg)
Title: Re: '92 Mild Widebody Build
Post by: theastronaut on October 11, 2021, 11:05:35 PM
Last update to bring the post up to date.  This past weekend I went to the Columbia SC Pull-A-Part after a guy that had bought parts from me in the past texted and said that there were two '94 NAs in the yard. I needed a nice set of front marker lights and turn signal lenses and he said that one of the cars had a set still.  Seems like someone brought them down from Ohio; they were rusty and one had an Ohio license plate in the trunk.  Both had been sitting a really long time; the tires on one were super dry rotted and the tires on the second were brand new but weathered and didn't have a modern date code.  There were signs that the engines had been partially disassembled for a long time as well.  Unfortunately the hoods had been left up and water had gotten into both engines.  The window regulators had been taken out of both cars but everything else was there. 

(https://i.imgur.com/Y09pionh.jpg)

(https://i.imgur.com/GOd6uDoh.jpg)


I grabbed the tail lights, filler panel, valve covers, front marker/signal lights, headlight popup modules, airbag modules, intake boots, a pair of '94 bumper grills, and a few other parts from an Aspire and an Escort wagon. Most of this will be for sale to help fund the project, PM me if you see anything you need.  If the weather is good this Saturday I may go back for the one unbroken windshield and front brakes/knuckles from the Aspire.

(https://i.imgur.com/0YavL5Gh.jpg)

(https://i.imgur.com/8VMdOB5h.jpg)

(https://i.imgur.com/SNYzqewh.jpg)


The lenses from the junkyard were in good shape but the reflector coating was starting to fade.  I used 3M foil tape and Mothers metal polish to make them reflective again. I still need a matching '94 passenger side marker lens to complete the set if anyone has one.

(https://i.imgur.com/PUifEpwh.jpg)


Left side restored, right side faded- noticeable improvement in how the lights look with the inside evenly reflective.

(https://i.imgur.com/aHj2btDh.jpg)


Before/after.

(https://i.imgur.com/h5OkXeOh.jpg)

(https://i.imgur.com/W3he64Lh.jpg)


Much nicer looking than the old lights.

(https://i.imgur.com/9EoKCHih.jpg)


After installing new bulb holders and bulbs.  All of the lights work now so the car can be driven legally.  I'll work on getting the bumpers prepped/painted and installed and get the car insured and registered.  I'd like to have it back on the road within a couple of weeks. 

(https://i.imgur.com/DrHU0IVh.jpg)


Title: Re: '92 Mild Widebody Build
Post by: theastronaut on October 11, 2021, 11:15:32 PM
Almost forgot, I traded the wheels I initially bought for the project for a set of '95 Miata M Edition BBS wheels, then sold the BBS wheels for a decent profit.  I had bought a set of 15x7 +17 Riken Mesh wheels in good condition earlier this year and the offset is nearly perfect for the pulled fenders and wider quarters.  I want to run a couple degrees of negative camber so I'll probably have to use a 10-15mm spacer to make the wheels fit flush and not rub the coilovers.  I'm looking into sticky 200tw tires for it, and was planning on using Federal RS Pro in 195/50 but they seem to be out of stock everywhere. 

(https://i.imgur.com/Ria9sHoh.jpg)

(https://i.imgur.com/He1N9Kfh.jpg)

(https://i.imgur.com/H910Ciih.jpg)
Title: Re: '92 Mild Widebody Build
Post by: greywolf27030 on October 12, 2021, 09:05:12 AM
Who says you can't put an aftermarket steering wheel on a Capri.....lol This has to be the most interesting project I have seen since getting into Capri's. You're the man.
Title: Re: '92 Mild Widebody Build
Post by: Aus Capri on October 12, 2021, 08:50:15 PM
Hey man I have always thought the stock bumpers are way to big as well, especially the rear one! I've been considering putting a duck bill spoiler on mine I think it would look heaps better than the stock one too. Your cars gonna look awesome man your inspiring me!
Title: Re: '92 Mild Widebody Build
Post by: Aus Capri on October 12, 2021, 08:53:24 PM
BTW what's wrong with the steering wheel adapters you can get? I've got one on my car and now I'm worried I shouldn't have.
Title: Re: '92 Mild Widebody Build
Post by: theastronaut on October 12, 2021, 10:19:46 PM
Who says you can't put an aftermarket steering wheel on a Capri.....lol This has to be the most interesting project I have seen since getting into Capri's. You're the man.

Not bad for a Festiva guy, eh?  ;D


Hey man I have always thought the stock bumpers are way to big as well, especially the rear one! I've been considering putting a duck bill spoiler on mine I think it would look heaps better than the stock one too. Your cars gonna look awesome man your inspiring me!

Thanks!  I shaved the stock spoiler holes and third brake light with plans to maybe fit a small duckbill style spoiler.  I've had this pic saved for awhile, that's about the height I would want.  I like the look without a spoiler too, the rendering that originally got me wanting to build a Capri is spoilerless. 

(https://i.imgur.com/pxt0t63h.jpg)

(https://i.imgur.com/dspeSNkh.jpg)


BTW what's wrong with the steering wheel adapters you can get? I've got one on my car and now I'm worried I shouldn't have.

US Capris have a weird Ford/Mercury steering column so they could be fitted with airbags, and there is no hub available that fits correctly.  Some Mustang hubs halfway fit but I tried one and it seemed sketchy so I made my own.  From what I understand Aus market Capris had Mazda based columns and Mazda style adapters fit no problem. 
Title: Re: '92 Mild Widebody Build
Post by: theastronaut on October 18, 2021, 11:13:02 PM
This weekend I removed the cruise control system and windshield washer to drop more weight.  I used a Festiva one piece throttle cable to replace the dual cable setup after I took the cable junction box apart and decided that I didn't want to attempt making it work without the cruise input cable. 

(https://i.imgur.com/xzPTI2gh.jpg)

(https://i.imgur.com/zCa0i0Bh.jpg)


I pulled the boot back and shot PB Blaster in it, then snapped it back in place and hung it up to let it drain into the cable overnight. 

(https://i.imgur.com/W5K32zNh.jpg)


Tonight I took a front strut off and apart to see what needed to be done to adapt the top mount to the coilover.   The coilover has M14x1.4 threads compared to the stock M12 threads.  The spring hats that came with the coilovers are both the wrong size, I'll have to use the pair with smaller holes and drill them to fit the M14 threads.   

M12 stock top nut vs M14 coilover threads. Notice that there isn't a step in the shock shaft to match the ID of the top mount bearing.

(https://i.imgur.com/OFAPdoNh.jpg)


The spring hats from the rear MK2/3 coilovers are the right size to fit up against the bearing in the stock top hat.  This is important to keep the spring from getting in a bind when turning.

(https://i.imgur.com/qUTMknsh.jpg)


I used the lathe to trim back and cut a taper into the bottom of the stock nut.  A nut with a tapered bottom is needed to center the shock shaft in the top hat. Stock struts have a small area on the shock shaft below the threads that matches the ID of the top hat bearing, but the coilovers don't have that and are loose in the top hat bearing.   This would have worked, but it made the nut too short, so I wouldn't be able to tighten the nut.  I'll pick up a M14 x 1.5 tapered lug nut at a parts store tomorrow to use instead.  I was hoping the stock nut would work to retain the o-ring seal that keeps dirt out of the bearing, but I can find a plastic or rubber plug to use instead. 

 (https://i.imgur.com/9HFnr6Eh.jpg)

(https://i.imgur.com/AMKS3xDh.jpg)

(https://i.imgur.com/QZkJIj3h.jpg)


Another modification- I'll weld large washers off center over the bottom two knuckle mounting holes, this adds enough material to safely slot the holes horizontally for a lot of camber adjustment.  Once I get all of this figured out to assemble the coilovers I'll make a detailed/condensed write up for anyone interested in making their own set. 

(https://i.imgur.com/68DWV1dh.jpg)
Title: Re: '92 Mild Widebody Build
Post by: greywolf27030 on October 19, 2021, 09:21:58 AM
Great work, how much weight do you think you can shed?
Title: Re: '92 Mild Widebody Build
Post by: theastronaut on October 19, 2021, 01:23:27 PM
Curb weight for a base model is listed at 2381.  I think I can get it down to 2200 pretty easily without cutting anything.  Dropping the factory bumpers and seats is a pretty big chunk, and I have a smaller/lighter battery that will save around 25 pounds.  I'm not installing any carpet and the wheels and coilovers are lighter than stock.  The steering wheel is lighter as well.  I haven't posted about it yet, but I gutted the driver side door, there's no regulator or motor or wiring in it now, just a pull strap with a couple of snaps to raise/lower the glass.  I'll make simple/flat door panels to cut down on noise.   I'll see what it weights like that, then maybe start cutting the inner bracing out of the trunk lid and other non-structural areas.  Brad Hazard pulled "over 270" pounds off his '94 XR2 but he removed the soft top, bumpers, trunk lid, soft top lid... I think he eventually got it down to 18-1900 pounds with everything possible removed, even the dash, but of course it was only barely driveable like that.
Title: Re: '92 Mild Widebody Build
Post by: greywolf27030 on October 20, 2021, 08:58:13 AM
Are you using a lithium battery?
Title: Re: '92 Mild Widebody Build
Post by: theastronaut on October 26, 2021, 10:37:32 PM
Are you using a lithium battery?

No, it's a Deka ETX12 agm.  Lots of Festiva guys use them, both with the original 1.3 and with 1.6 swaps.

https://www.lowes.com/pd/Deka-12-Volt-Motorcycle-Battery/50183741?cm_mmc=shp-_-c-_-prd-_-sol-_-ggl-_-PLA_SOL_146_Riders-Chore-Accessories-_-50183741-_-0-_-0-_-0&ds_rl=1286981&gclid=EAIaIQobChMIk42L2PnW8wIViJWzCh1fyAv7EAQYAyABEgLh7vD_BwE&gclsrc=aw.ds
Title: Re: '92 Mild Widebody Build
Post by: EShepherd on October 27, 2021, 07:25:48 AM
Are you using a lithium battery?

No, it's a Deka ETX12 agm.  Lots of Festiva guys use them, both with the original 1.3 and with 1.6 swaps.

https://www.lowes.com/pd/Deka-12-Volt-Motorcycle-Battery/50183741?cm_mmc=shp-_-c-_-prd-_-sol-_-ggl-_-PLA_SOL_146_Riders-Chore-Accessories-_-50183741-_-0-_-0-_-0&ds_rl=1286981&gclid=EAIaIQobChMIk42L2PnW8wIViJWzCh1fyAv7EAQYAyABEgLh7vD_BwE&gclsrc=aw.ds

That thing is only 180 cold cranking amps. Is that really enough to start the engine with? If so, that's fantastic. It looks like it weighs only a few pounds. Where do you have it mounted?
Title: Re: '92 Mild Widebody Build
Post by: greywolf27030 on October 27, 2021, 08:11:51 AM
I think Charlie Whitney uses something similar. doesn't he?
Title: Re: '92 Mild Widebody Build
Post by: Aus Capri on November 03, 2021, 10:23:33 AM
Are you using a lithium battery?

No, it's a Deka ETX12 agm.  Lots of Festiva guys use them, both with the original 1.3 and with 1.6 swaps.

https://www.lowes.com/pd/Deka-12-Volt-Motorcycle-Battery/50183741?cm_mmc=shp-_-c-_-prd-_-sol-_-ggl-_-PLA_SOL_146_Riders-Chore-Accessories-_-50183741-_-0-_-0-_-0&ds_rl=1286981&gclid=EAIaIQobChMIk42L2PnW8wIViJWzCh1fyAv7EAQYAyABEgLh7vD_BwE&gclsrc=aw.ds

That thing is only 180 cold cranking amps. Is that really enough to start the engine with? If so, that's fantastic. It looks like it weighs only a few pounds. Where do you have it mounted?

I just searched the battery it weighs 4.3kg or 9.48 pounds, it's got me wondering how heavy my battery is! I'm gonna weigh it!
Title: Re: '92 Mild Widebody Build
Post by: greywolf27030 on November 04, 2021, 10:56:17 AM
[I just searched the battery it weighs 4.3kg or 9.48 pounds, it's got me wondering how heavy my battery is! I'm gonna weigh it!
[/quote]

Mine weights about 26kg, about 50 lbs.