Front Trunk Refurbishment T5 Coupe

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Ken Tuvman
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Dirty Job!

#1 Post by Ken Tuvman »

Latest project- interior of front trunk:

Plan is to replace front wiring harness, get horns swapped for presentable ones, LED headlights. Repaint, Minor patchwork with POR.

Looks like factory used tar and paper - pretty smelly and sticky but so far not seeing any rust!

Fuel tank will come out and this will be a Big Job and improvement for my rolling restoration.

Wish me luck!
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Mike Wilson
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Re: Dirty Job!

#2 Post by Mike Wilson »

Can't wait to see the "after" pics!

Mike
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Ken Tuvman
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Re: Dirty Job!

#3 Post by Ken Tuvman »

Mike Wilson wrote: Tue Jun 27, 2023 10:39 pm Can't wait to see the "after" pics!

Mike
Me too Mike😃
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Re: Dirty Job!

#4 Post by Ken Tuvman »

Forgot to post the horns!
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Don Gale
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Re: Dirty Job!

#5 Post by Don Gale »

I love Rod Emory's method for cleaning the gastank:

https://www.facebook.com/reel/203951755869933
1958 356A 1600 Super Sunroof Coupe
former 1966 Euro 912 Sunroof
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Don Gale
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Re: Dirty Job!

#6 Post by Don Gale »

dirty_deeds.jpg
1958 356A 1600 Super Sunroof Coupe
former 1966 Euro 912 Sunroof
former 1978 Intermeccanica Speedster w/'68 912
Member Since 1983, #4039

"Nostalgia isn't what it used to be"

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Ken Tuvman
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Re: Dirty Job!

#7 Post by Ken Tuvman »

Don Gale wrote: Tue Jun 27, 2023 11:45 pm I love Rod Emory's method for cleaning the gastank:

https://www.facebook.com/reel/203951755869933
Thanks Don - first thing I did 3.5 years ago when I got car was sending tank out for professional renewal- now just getting to various aspects of my car that need attention and bother me - especially the way PO attached the plywood relay setup to inner fender wall - a big mess!!!
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Ken Tuvman
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Re: Dirty Job!

#8 Post by Ken Tuvman »

Made some progress today - fuel tank was drained and removed - haven't quite figured out yet to remove existing wires but working on it.

Some of the photos may provide insight to my questions:

Few questions for anyone who's been down this rabbit hole:

1. Have a lot of cleaning up still in Frunk - not seeing many drain holes where the spare tire goes - afraid the water will pool up when I start with the POR prep products that require rinsing.
2. There are two ground wires riveted - guessing they'd be for horn or headlights - any clarification appreciated.
3. Fuel cushions? Is this what factory used? It appears to be a felt material. Probably looking for something with more shock absorbent properties?
4. Firewall material - it does look in decent shape - thinking I should just leave it alone - remove fuel straps, metal prep and POR over existing - same comment for the inner fenders coated with tar that seems to be in pretty good shape.
5. Big black cable was the positive to battery - looks like it'a in pretty good condition - does it need to come out to make room for the new wires going in - from what the new harness looks like, thinking the bulk of wires stay in Frunk and I'll be feeding the wires to the fuse box from front to back - yes / no ?
6. Headlight insides (I want to call them buckets but they're the piece normally painted grey - mine are black - is there a correct gray rattle can color to use?
7. Data plate - if it could be cleaned up, how would you do it or is it looking better "patina" as it shows?

That's about where I'm at for now - thank you!
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Martin Benade
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Re: Dirty Job!

#9 Post by Martin Benade »

I’ll comment on #2 the ground wires would not be riveted. They are the pair near the horns but inside the trunk wall? Those would be a screw (small bolt?) and nut. Maybe rusted so they look like rivets? They’d be part of your new harness and need a ring terminal on each.

Is the last picture the heavy main cable to the starter? I see it’s modern wire.
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Ken Tuvman
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Re: Dirty Job!

#10 Post by Ken Tuvman »

That heavy cable was bolted onto the positive battery harness - doesn’t seem stock or is it? There were also red wires that powered the relay setup.
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Re: Dirty Job!

#11 Post by Martin Benade »

How heavy is that? About 3/8 or 1/2” diameter?
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Re: Dirty Job!

#12 Post by Ken Tuvman »

Yup - ginormous- can’t be oem?
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Re: Dirty Job!

#13 Post by Ken Lubke »

Well I see you’re starting your project that you were discussing. Should keep you busy for a bit. Good luck

Kenny

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Front Trunk Refurbishment T5 Coupe

#14 Post by Ken Tuvman »

I thought I'd chronicle my latest project to my '61 T5 Coupe here:

I've owned the car about 4 years and it's needed lot of attention - new engine, seats, shift linkage, steering box overhaul, link/king pins, suspension, brakes, instruments, fuel tank, carbs - it's old!

Previous owner modified front wiring harness by adding relays mounted to plywood. He drilled 4 holes through front left fender and mounted them with standard sized nuts and bolts. He didn't put a new loom around the wires - instead he used string and neatly wound everything from one end to the other - can't imagine how much time it must've taken him. At any rate, I didn't like the setup and came up with a plan of attack for the front trunk and harness.

I met Jules Dielen when I was looking for the correct speedo - Ralph from NH Speedometer told me what I had in the car was from an older A model - not correct. Wound up purchasing LED's from Jules as well as the third brake light.

For this project, I decided to purchase LED headlights from Jules and was able to get the front wiring harness from Greg Bryan. While I'm at it, I pulled the horns and am exchanging them for a restored set from Julian Hardy.

Not sure if OEM but the trunk always had a foul tar smell to it - the inside front fenders are coated with tar material or some kind of protection and are painted over black - they've held up pretty well so not planning to remove what would otherwise be a huge job. The padding beneath the fuel tank is just several strips of felt so I need to some up with something to help absorb the bumpity bumps of driving down the road. Same goes for firewall - Doug M. suggested automotive jute so I may to that route.

I did remove the ridged rubber under the very front where the spare tire would go, in front of the battery box - it was pretty gross. I then used some solvent to wipe up the tar that seemed to never cure - I will say there is no rust in the trunk - not bad for 62 year old Midwest car!

Here's where I'm at so far with the project:
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Re: Front Trunk Refurbishment T5 Coupe

#15 Post by Ken Tuvman »

I'm leaving the factory ID plates in place and will mask them off when I treat the interior trunk.

Trying to decide best method and could use some input here from the group.

I've had good luck with POR for treating the floor pans in the cabin - was thinking to do the same But - I watch Tom Perazzo's "Garage Time" videos and saw he used Raptor bed liner to coat his. I admire what Tom does but I'm not the perfectionist and artisan like him. I know it's a collectible car and I want to do a professional job but my goal is to keep this as a driver, not a show car.

With that said, I'm considering using the POR 15 process of degreasing priming the metal and then applying the POR - BTW, POR stands for Paint Over Rust. I did contact technical support and the person I spoke with suggested using the spray can bed liner for the interior fenders that are coated and seem to be in pretty good shape (would be hard to remove what's already applied).

I will want to replace whatever material is on the bulkhead / firewall and figure out a durable padding under the fuel tank - if you suggest Automotive Jute, which product do you like and recommend and where to buy.

That's where I"m at at the moment - figuring out plan of attack! Your comments are appreciated! Thank You > Ken Tuvman
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