Jerome's Sunbeam Pages
3.6. Rebuild Checklist
In first entering the world of the "classic" auto, I heard a lot of horror stories about repairs and restorations. Later I read about and saw some successful ventures, and realized the latter lacked an important element held by the former: Planning, or at least some long-view forethought. Unfortunately, I am not wealthy enough to spend my time making money to be simply "spent" on a hobby as one crisis or mistake fades into the next.
So, I started using the tools I know best to do a little thinking (and dreaming). The following quite-large table represents a "To Do" list made from a spreadsheet where the major blocks are modelled after the Rootes' Workshop Manual for my Alpine. There is no timeline information: merely a list of all the things that will bug me for the next while. For the procedure by which they will be addressed, see Rebuild Sequence.
This is a rather large table (120+k).
| as of: 1998.12.20 | |||||||||||
| Cooling | |||||||||||
| Items/Tasks: | Inspect | Clean | Lube | Tighten | Replace | Repair | Re-Cover | Comments | |||
| Radiator | |||||||||||
| Clean & Paint | DONE | DONE | DONE | DONE | DONE | ||||||
| Hoses | |||||||||||
| Upper | X | ||||||||||
| Lower | X | ||||||||||
| J | X | ||||||||||
| Heater | X | ||||||||||
| Water Pump | |||||||||||
| Body | DONE | ||||||||||
| Fan | DONE | ||||||||||
| Belt | X | ||||||||||
| Seal | X | ||||||||||
| Engine | |||||||||||
| Items/Tasks: | Inspect | Clean | Lube | Tighten | Replace | Repair | Re-Cover | Comments | |||
| Head | |||||||||||
| Block | DONE | X | DONE | ? | |||||||
| Valves | DONE | X | DONE exhaust | ||||||||
| Springs | X | X | ? | ||||||||
| Rocker Arms | X | X | ? | ||||||||
| Arm Adjusters | X | bad heads | |||||||||
| Arm Rack Springs | X | ||||||||||
| Push Rods | X | ||||||||||
| Lifters | X | ||||||||||
| Camshaft | DONE | ||||||||||
| Cover | DONE | X | |||||||||
| Cover Gasket | X | ||||||||||
| Gasket | X | ||||||||||
| Motor | |||||||||||
| Block | DONE | DONE | DONE | DONE | |||||||
| Crankshaft | DONE | DONE | DONE | ||||||||
| Bearings | DONE | X | |||||||||
| Thrust Washers | DONE | X | |||||||||
| Seals | |||||||||||
| Pistons | DONE | X | |||||||||
| Rings | DONE | X | |||||||||
| Rods | DONE | ||||||||||
| Wrist Pins | DONE | ||||||||||
| Oil Pump | DONE | DONE | |||||||||
| Carburettors | |||||||||||
| Body | DONE | DONE | |||||||||
| Gaskets | DONE | ||||||||||
| Jets | |||||||||||
| Linkage | DONE | DONE | DONE | DONE | |||||||
| Filters | |||||||||||
| Intake Manifold | DONE | DONE | DONE | ||||||||
| Manifold Gaskets | X | ||||||||||
| Exhaust | |||||||||||
| Headers | DONE | ||||||||||
| Gaskets | X | ||||||||||
| Muffler | X | ||||||||||
| Piping | X | ||||||||||
| Timing | |||||||||||
| Chain | X | ||||||||||
| Dampers | X | ||||||||||
| Cover | DONE | ||||||||||
| Cover Seal | X | ||||||||||
| Fuel | |||||||||||
| Items/Tasks: | Inspect | Clean | Lube | Tighten | Replace | Repair | Re-Cover | Comments | |||
| Pump | |||||||||||
| Body | DONE | DONE | DONE | ||||||||
| Gaskets | DONE | X | |||||||||
| Filter | DONE | DONE | DONE | ||||||||
| Lines | |||||||||||
| Tank | X | DONE | X | ||||||||
| Carbs | X | DONE | X | ||||||||
| Tank | |||||||||||
| Tank | X | X | |||||||||
| Sender | X | ||||||||||
| Cap | X | ||||||||||
| Clutch/Propeller | |||||||||||
| Items/Tasks: | Inspect | Clean | Lube | Tighten | Replace | Repair | Re-Cover | Comments | |||
| Clutch | |||||||||||
| Disc | X | DONE | |||||||||
| Master Cylinder | X | X | |||||||||
| Slave Cylinder | X | X | |||||||||
| Hydraulics | X | ||||||||||
| Propeller Shaft | |||||||||||
| Shaft | X | ||||||||||
| U-joints | X | ||||||||||
| Gearbox & Overdrive | |||||||||||
| Items/Tasks: | Inspect | Clean | Lube | Tighten | Replace | Repair | Re-Cover | Comments | |||
| Gearbox | |||||||||||
| Unit | DONE | DONE | DONE | ||||||||
| Seals | DONE | ||||||||||
| Overdrive | |||||||||||
| Unit | DONE | DONE | |||||||||
| Seals | DONE | DONE | |||||||||
| Hydraulics | DONE | ||||||||||
| Interlock | DONE | ||||||||||
| Electrical | DONE | DONE | |||||||||
| Front Suspension | |||||||||||
| Items/Tasks: | Inspect | Clean | Lube | Tighten | Replace | Repair | Re-Cover | Comments | |||
| Shocks | |||||||||||
| Springs | |||||||||||
| Ball Joints | |||||||||||
| Upper | DONE | DONE | DONE | ||||||||
| Lower | DONE | DONE | |||||||||
| Rear Axle | |||||||||||
| Items/Tasks: | Inspect | Clean | Lube | Tighten | Replace | Repair | Re-Cover | Comments | |||
| Differential | |||||||||||
| Bolts | X | X | |||||||||
| Seals | X | front | |||||||||
| U_Joints | X | X | X | X | ? | ||||||
| Axles | |||||||||||
| Hubs | X | X | PR DONE | ||||||||
| Shafts | X | X | X | ||||||||
| Rear Suspension | |||||||||||
| Items/Tasks: | Inspect | Clean | Lube | Tighten | Replace | Repair | Re-Cover | Comments | |||
| Springs | |||||||||||
| Leaves | DONE | DONE | X | ||||||||
| Shackles | DONE | DONE | X | ||||||||
| Shocks | |||||||||||
| Rear | X | X | X | Refill | |||||||
| Steering | |||||||||||
| Items/Tasks: | Inspect | Clean | Lube | Tighten | Replace | Repair | Re-Cover | Comments | |||
| Box | |||||||||||
| Rack | |||||||||||
| Wheels | |||||||||||
| Arms | |||||||||||
| Column | |||||||||||
| Wheel | |||||||||||
| Brakes | |||||||||||
| Items/Tasks: | Inspect | Clean | Lube | Tighten | Replace | Repair | Re-Cover | Comments | |||
| Front | |||||||||||
| Rotors | X | ||||||||||
| Pads | X | ||||||||||
| Hydraulics | X | ||||||||||
| Calipers | X | ||||||||||
| Rear | |||||||||||
| Drums | DONE | DONE | |||||||||
| Shoes | DONE | DONE | |||||||||
| Hydraulics | X | DONE | X | D-R bleed nipple | |||||||
| Handbrake | X | X | X | ||||||||
| Wheels and Tyres | |||||||||||
| Items/Tasks: | Inspect | Clean | Lube | Tighten | Replace | Repair | Re-Cover | Comments | |||
| Rims | X | Red | |||||||||
| Tires | X | DONE | |||||||||
| Electrical System | |||||||||||
| Items/Tasks: | Inspect | Clean | Lube | Tighten | Replace | Repair | Re-Cover | Comments | |||
| Engine | |||||||||||
| Starter | X | X | |||||||||
| Coil | DONE | DONE | |||||||||
| Regulator | X | X | |||||||||
| Dash | |||||||||||
| Gauges | X | X | X | X | |||||||
| Switches | X | X | X | X | cig. lighter | ||||||
| Wiring | X | X | |||||||||
| Exterior | |||||||||||
| Lights | X | X | |||||||||
| Wiring | X | connectors | |||||||||
| Body | |||||||||||
| Items/Tasks: | Inspect | Clean | Lube | Tighten | Replace | Repair | Re-Cover | Comments | |||
| Interior | |||||||||||
| Dash - Top | X | X | |||||||||
| Dash - Face | X | X | |||||||||
| Windshield | seals | scratches | |||||||||
| Carpets | X | ||||||||||
| panels | X | X | |||||||||
| seats | new bolts | seatbelts | |||||||||
| floorpans | DONE | DONE | sealer | ||||||||
| Ash Tray | X | X | re-chrome? | ||||||||
| Stick | X | X | Alpine knob | ||||||||
| Console/Armrest | fastening | vinyl | |||||||||
| Exterior | |||||||||||
| Fillers | DONE | remove | |||||||||
| Holes | DONE | ||||||||||
| front damage | DONE | ||||||||||
| doors | DONE | DONE | |||||||||
| top | X | ||||||||||
| windows | X | X | |||||||||
| Engine Compartment | |||||||||||
| compartment | DONE | DONE | DONE | ||||||||
| Trunk | |||||||||||
| compartment | DONE | DONE | DONE | ||||||||
| Panels | X (none) | ||||||||||
| Attachments | |||||||||||
| Bumpers | re-chrome | ||||||||||
| Brightwork | X | clips | |||||||||
| Handles | X | X | seals | ||||||||
| Wipers | new blades | ||||||||||
| Heating & Ventilation | |||||||||||
| Items/Tasks: | Inspect | Clean | Lube | Tighten | Replace | Repair | Re-Cover | Comments | |||
| Heater Core | |||||||||||
| Valve | |||||||||||
| Blower | |||||||||||
| Ducts | |||||||||||
| |
3.6. Rebuild Checklist JOY/CVP/YSEV/0.31 - November 7, 1999 |