Dismantling the Opel GT

The Beginning of the End Here we began removing engine parts and stuff. We took off the radiator, alternator, brackets, exhaust, bumper, head light assemblies, marker lights and the rest of the interior, pretty much everything but the actual engine. Removing the exhaust gave us both pause and in the end I went through several cutting disks before I managed to chop the thing out. The Freeze-Off really helps when working on these older vehicles where there is rust and uncooperative parts. We couldn’t get the head off because it needed a special tool called a Triple Square Driver Set, and eventually I ended up ordering it off the internet as no local store carries them. In the process of removing the headlights, I learned that this was a great place for leaves to collect and that I will need to be mindful of keeping the debris cleaned out so it won’t hold moisture and allow it to rust. Luckily, the previous owner took good care of storing the car out of the elements, so there is very little rust anywhere on the car. I accidentally broke two bolt heads off when we removed the bumper so I will need to replace them when it comes time to reattach it. Goodies Acquired: Triple Square Driver Set On a side note, as Tamera and I work at sister companies, right next door to one another, we know all the same people. I frequently get asked if she really helps me. The answer is yes. She gets dirty and greasy, breaks her nails, bruises her knuckles and does as much as is physically possible for her to do. Her smaller hands have been valuable for getting into tight spots that I simply couldn’t get to. She helps line things up and even if it’s just to hold a flashlight, we have been committed to doing this project together, and she has helped every step of the way.

Engine Removal

Our Triple Square Driver set arrived and we got the head removed. Now it was time for milestone #1…the removal of the petrol powered engine. I will say that this was no easy feat. We had to move in baby steps, inch by excruciating inch, in lowering this thing to the floor. It was hard work, and we had to keep readjusting the jacks and the engine. Unfortunately, Tamera didn’t realize that the camera’s batteries died, so we lost much of this segment. This footage would have probably made a good bloopers segment. Four different times we thought we had it only to find out there were more bolts that seemed to magically appear out of thin air each time. At one point, when Tamera was helping guide the engine from the top as I was lowering from the bottom, the engine unexpectedly shifted and halfway pulled her into the car with it.

After much work, we finally got it out, and started getting the car cleaned up. When all was said and done we must have went through 4 or 5 cans of degreaser. It was a messy job, but well worth the end result.

Goodies Acquired:
Bottle Nose Jack
Floor Jack w/ stands

The Hall Effects Pedal Installation

“If at first it doesn’t fit, cut something until it does…”

Finally, we had the money for the motor and the controller. We ordered it the moment we had the money, because something always pops up when we have any money in the bank. Be it tires, car repair, vet bills, something, anything. And sure enough, having just ordered the motor and stuff about a week ago, Tamera lost a crown on her tooth, and we all know how much dental work can cost. We were both very glad for having already ordered the parts, because we most likely would have put it off. Moral of the story - NEVER put it off, there is always something that will try to hold you back…always, always keep pushing forward no matter what!

I ordered the following: WarP 9 DC motor, 156v Z1K Controller, liquid cooling kit, Hall effect pedal, Zolox speed sensor, 500A fuse and a strut-N-Rod Plus. They threw in a free speed senor mount. Everything but the motor and the controller came in on the 28th of November.

In my head, the pedal fit perfectly, in reality, it did not. I had to modify the body of the car a bit where it needed to go. The main problem was that the steering column ran right where I need the pedal. I went with the controller with the Hall Effect pedal option and got a Hall Effect pedal, because using the original pedal with the controller would have required the use of cables. This car did not originally use any cables so I would have had to set all that up. I figured it would be easier not doing so. After an entire day of cutting, grinding and welding, while, I don’t really think it ended up being any easier, I am glad I went the route I did. In the end, we are both happy with the placement and feel of the new pedal.

Goodies Acquired:
Air compressor
Air tool set
Mig Welder
Drop light
Garage heater

Roll On Paint Job?

I haven't posted much on this project lately. But I have been working on the Opel. I have been painting it in my garage with a roller. I came across a forum thread over how to paint your car with a roller. So wanting to save money on this project I decided to go for it and put that saved cash towards battery s.

Below is a video of the paint jobs progress I'm not 100% done here but getting close. The paint Job came out better than I could have imagined.

Goodies Acquired:
Polisher / Buffer

Motor Installation

Well the motor installation went without a hitch. Tamera operated the engine lift and dropped it in the first time. After hashing out a few design ideas we settled and I notched out a semi circle in the motor's cross member  then reinforced the bottom.  I built the top motor mount that holds the motor in place and will also hold the electric components after I build a flat platform for them to mount on.

After we finished the install and the motor was secured I talked Tamera into taking a test roll out. hehe