SeventhSon

Those broken off exhaust manifold bolts are on the right side Paul. The left side bolts all came out, which I was glad for because of that steering box. My post from last night didn't make that clear now that I got some sleep!

Yes Paul, both on the right side head, thankfully away from the steering box anyway. Going to be tough enough as it is. Whew! What a day! At lunch today I rented an engine hoist - I had a couple of gracious offers to lend one to me but either one would have entailed traveling some distance and I wanted to get right after these motor mounts, so I rented one nearby. And when you have a time limit on a rental you have to get the work done! My thanks to the good folks for their offers - hopefully I can take a rain check for a future task! After I got home from work tonight and had something to eat I went to it. First I removed the hood, something I was intending to do in a couple of weeks when I started working on the topside. That was fun by myself! Setting that aside, I removed the radiator hoses, fan shroud, and radiator. Gave myself some working room. Then I set up the hoist, attached the chain to the two front intake manifold bolts, and lifted the front of the engine. Worked like a charm! Since I had the engine up I decided to install the new bell crank assembly. It really helped that the engine was up out of the way, the install was pretty straightforward. Next I attempted to install the steering arm but couldn't get it to fit properly onto the bell crank shaft. Round and round I went with that, the steering arm would go partially onto the shaft but not all the way. So I decided to fool with the motor mounts. They were a bit easier - still I had to bring the engine up, bring it down, align the mounts, etc. Finally they were in. Then I went back to the steering arm, I took a crescent wrench and turn the bell crank shaft nut back and forth to try to hit the right spot. After a couple of jiggles and turns I saw the steering arm settle down onto the shaft fully. Success! I installed the pinch bolt, put all the washers and nuts on the motor mounts and called it a night. A satisfying night.

Thanks Paul - feels good to be inching along. I have not one, but two, bolts sheared off in the head. Gonna have to deal with them soon, just haven't decided how yet.

Thanks John, yes I have plugs, wires, points, rotor, cap, etc in the parts boxes - just waiting for the right moment to put them in. I didn't want to put some stuff in and then damage it while working on other stuff. Let's see....should I do the plugs before the exhaust manifolds, or after? I guess after, since the plugs are above the manifolds.

Well, the freeze plugs are in - not a picture perfect job, but adequate for an amateur. I kind of wish I had a "do-over" on that one. In fact, I may do it over! I reserved an engine hoist for rental today, hopefully I can get the motor mounts installed and move forward. Which is what "Avanti" stands for in Italian, "forward". Sounds good to me....

Looking good John! That finish is like glass! I'm am totally envious of that interior too - hope mine is all fresh and new like that someday. Enjoy the Shootout - I used to listen to those every year on the radio back when Earnhardt was alive - those were the days...

I got an old hack saw blade, wrapped some duct tape around one end for a handle, and went after it. Great idea, this hack saw blade, strong but flexible and able to scoot around the various curves and crannies in the water jackets. After about 15 minutes on each side I wasn't really finding any packed in sediment - nothing much was coming out. So I decided to go ahead and flush it out with a hose. I ran water through each opening, up and down and all around until the water ran clear. I think things are pretty clean - looks clean anyway. Mostly what came out was fine sediment, which is what I was finding on the hack saw blade. There were a couple of larger pieces that made their way out - they're shown in the last picture. Maybe a couple of casting pieces?

John - I have an old blade that I can press into service for that. I think maybe that engine was rebuilt at some point, hence the orange oil pan and relatively clean look of the innards. I hope so anyway....

I only got in a little over an hour on the Avanti tonight. I just looked around for some surgical tools and went to town - scrape, dig, scrape. I got some crud out, mostly around the freeze plug areas and toward the bottom of the block, it seems. Makes sense, where all the sediment settles. the brake adjustment tool was handy, angled and strong enough to dig around. That other piece with the 90 degree angle was good too, thin enough to dig in tight areas. The hanger was useless, too flimsy, and the scratch awl was too straight. Tomorrow I'll try some brushes! I figure another night of digging and scratching and I'll be ready for flushing everything out on Thursday. Fun job!

Huh, didn't know that! I'll have to rent the film so I can say, "I know that car!".

Thanks John - it's good to see what's behind the plugs, doesn't look too bad so far. I'll be glad to get it flushed out and install the new plugs, so it feels like I'm making some progress. A little at a time....

Well, I started to regain some of my strength so I decided to see what I could do on the Avanti. I had previously removed one of the motor mounts nuts, then tried 2 more only to find the mounts spinning around as I gave it all I had on the wrench. So I once again turned to the grinder and ground off the top two nuts, or partially so, enough that they released their grip and I was able to wrench them off. The other lower nut came off cleanly, so I had two motor mounts free - now to get the engine up enough to get them off. Well, the first one came out (barely) only because the metal bolting plate had separated from the rubber insulator. It was apparent that the new mounts weren't going in, as they are fresh rubber and a good half inch thicker than the old crusty mounts. I was having trouble getting the engine up enough from the underside - looks like brother Brian was right about using a hoist (big brother is always right). After lunch and a visit to Sears Hardware for more supplies (tip: buy stock in Sears!) I went after the freeze plugs. I was happy to get them all out and the first crustiness cleaned out - I felt like I got something accomplished anyway. I'm glad I am replacing them, especially the left side (there's that left side again) ones, they were barely holding coolant back. The water jackets didn't look too bad from what I could see - tomorrow I will look around with an inspection mirror and scrape, scrape, scrape until I can't find anything else to scrape. Then I'll flush them out well, wire wheel the openings a little to clean them, apply some Permatex No. 2 and install the new plugs. Let's hope it goes that easily.

Thanks Brian - yeah, I'm pretty wiped out. Just been lying around all day feeling bad. Bleah! When I get better maybe I will check out Matt's welding skills - if he's still traveling down this way to see Sugar :-) Anyway, I have lots to do on the car - the wrung off bolts can wait for awhile!

John, thanks for talking some sense into me. I just have to focus on one thing at a time, the first thing being to rest and get over this cold I have. For now I am going over to your "Avanti Refresh" and check out those bumpers!

Stude8, thanks for the tips. I'll try the heat first - I was watching a YouTube video last night where a guy welded a washer, then a nut onto a broken off bolt and was able to bring it out. I don't have a welder (or torch for that matter!) so I'll have to work that out, possibly get someone to come by and work on it.

Brian, I'm going to try some heat. First, I have to try to get a hole drilled in the old bolt studs, but they are extremely hard and I'm working with a 90 degree drill setup. I do have some easy out type of extractors - gotta get the holes drilled though. Tight spot and super hard material, dunno, might end up pulling the head off! Or, crating the whole motor and sending it to Nimesh! Tried doing some stuff last night but I have a head cold taking hold so I'm dragging right now. Might leave those exhaust bolts for another time and concentrate on the motor mounts (which are putting up their own stout fight) and freeze plugs.

The Battle of the Exhaust Manifolds continues. I spent 15 minutes at lunch finishing up grinding on the last bolt head, then grabbed the giant pry bar (digging bar) and loosened the manifold off the studs (one broken off, one ground off). The manifold came loose but the breather tube was holding everything in place. So tonight I removed that (which I had just put back on when I did the oil pan) and the manifold fell off. Yay! Then I turned to removing the bolt studs with my new stud extractor I acquired today in exchange for the broken one. That's when things got ugly. Yep, I wrung both of them off. Sigh. Honestly, I'm surprised I didn't wring more of the bolts off, tight as they were. Now I get to drill them out - thanks to Providence they weren't on the other side, with the steering box in the way. The fun continues... I called Dave Thibeault yesterday to ask about wheels and an exhaust system. I almost forgot to ask him about deleting the heat riser. He said that was a good idea, they cause a lot of trouble. So, that was a good bit of news - I asked if he had a spacer to fill in for the heat riser and he said he makes them just for that purpose. So, I ordered one of those and a complete stainless steel exhaust system. I'll hold off on the wheels for a few weeks - if I don't make some progress on getting this car back together I won't need 'em!

Well Dale, I guess my stud extractor was built different from yours. It has (or had) a thin rubber ring holding it together (must be the Chinese way of doing things). No pressure ball like the ratchet/socket combo - just a flimsy rubber ring that ripped apart when I gave it a knock with a drift pin and hammer. I'll just drop by Sears tomorrow and trade it for a new one - they still warranty their tools for life, hmmm? So tonight, after I got tired of breathing grinding dust from grinding on one of the manifold bolts, I decided to climb underneath the car and have a look at the last remaining bolt on the manifold. I had tried to remove it from the topside, but couldn't get anything to grip it. From underneath I saw there was a bit of grease on the bolt head so I got a small wire brush and cleaned it up. Then I noticed I had a clear shot at the bolt from the gap in between the frame and inner fender. I grabbed a ratchet and extensions and, since I couldn't get a socket to grab it, I got the bolt extractor set. The same one I was bad mouthing the other night. It must have taken offense, because it grabbed the bolt. I thought, "Hmmm...this feels like it might take hold here." I grabbed the 2 foot Pipe 'O Leverage, slid it over the ratchet handle, and exerted pressure. The bolt turned! All the way out! The extractor socket grabbed so tight I had to bang on the bolt to get it loose. So, I take back what I said - the bolt extractor is redeemed.

30k well spent! You have saved an historical icon - well worth saving! I expect I'll have as much in mine, if not more, when it's all said and done. I feel it's worth it, as long as I have a little expendable income to put toward it. I'll be very happy when mine reaches the point yours is. Congratulations!

Wow, what a process. They were very meticulous - of course, that's how they earn their living. That's a very rich green, the Jag will be very jealous of her!

Thanks Vern, I'll try that tonight. It should work - I hope.

Thanks for checking out what I'm doing Jay, it means a lot to know people are reading and taking an interest. Someone else, I think it was "straightshooter" said not to use Fram filters. That Fram filter was a gift from my friend John (known on here as unimogjohn), as a sort of "welcome to the Avanti club" gift. After I use them I was thinking about getting the filters from Studebaker International for about 10 bucks that are like original. Just to support SI. But I'm not sure if they are any good - made by AC? Not sure. I'll check them out, for sure. Thanks again for checking in Jay. John, I'll try that procedure to check for cracks. If I find anything you'll hear my scream all the way in Hawaii! Thanks.

When I get there it will be because of folks like yourself, who help and encourage folks like me. Thank you. You speak words of wisdom about taking the wife out - that's what I did on Sunday after recovering from the near debacle on the garage door opener. And that's why I'm not working on the Avanti tonight, it being St. Valentine's Day and all! Can't wait to see your Avanti all finished - she's gonna be a looker!

WOW! That looks amazing! Even before the nice chrome bumpers get put on, along with the other shiny stuff! I am envious!

Thanks Dale and Vern, I'll take a close look at that tonight. I didn't realize the unit may come apart. I would put it in a vise, but I don't have one! Or any place to affix one! They are handy to have around though... John, I hope yours was an isolated case! I'll take a look at both heads before putting the manifolds on, even though I probably wouldn't be able to see a hairline crack.