Saturday, August 10, 2013

Odds And Ends, Part 4

Friday after work I applied a second coat of POR-15 on the flip side of the washers for the rear sway bar end links. Then I used a q-tip dipped in POR-15 to coat the inside of the sleeves for the end links. I thought it would be a good idea to at least have a single coat on the insides.

Thursday, August 8, 2013

Painting The Subframe Connectors, Part 2

Yesterday I started by prepping the rear subframe connector mounts for paint. I masked off the area I did not want to paint with painters tape and then covered that with a layer of duct tape for durability.

Tuesday, August 6, 2013

Have Talent - Will Weld

My friend Jake said he would be willing to finish the welding for me, so today after work I stopped at Troy's to get his permission to use the welder he left at my place. I did not feel comfortable just using it without asking. Troy said he did not mind and then mentioned that he had spent the morning finishing work on the rear end. I am planning to install the rear end this weekend.

When I got home I sent Jake a message letting him know that we had the okay to weld. I put away the brackets and gear selector that I painted yesterday and started hanging the three brackets I planned to paint today. Dad had mentioned that he would stop by after a bit and help with the painting. 

Monday, August 5, 2013

Odds And Ends, Part 3

I got some good news today! Bob from Fine Lines called me back to tell me he found the correct fuel line for KITT. It turns out that they had that particular line marked as being only for the V6 Firebirds. The assembly manual parts diagram I sent in confirmed that not only was that style used on the V6s but also on the Cross-Fire V8s. He said it was their mistake for not having it labeled properly and that there was no way for me to know it would be the wrong line. Tomorrow they are shipping out the correct line at no cost to me and I do not need to return the incorrect line. I have to say I am pretty impressed with Fine Lines right now and would recommend them to anyone looking for new hard lines for their classic cars. 

I am determined to speed up the process of getting the rear end installed as well as the remaining welding finished. I decided to see if there was anything I could use to grind down the rear subframe connector mounts. I only need to have the outsides welded, the interior sides were done when Troy was here the first time. 

Here is the driver side rear subframe connector mount.

Sunday, August 4, 2013

Odds And Ends, Part 2

I wanted to make sure that I finished the brackets I started prepping yesterday so I can paint tomorrow, provided the POR-15 arrives. I started by using the wire wheel on the last of the three brackets.

Saturday, August 3, 2013

Odds And Ends

Today I decided to get some minor stuff done that I had either been putting off, or that was just not critical at the moment. I started by hanging the rear quarter plastics on the ceiling to get them out of the way. I secured each one with a bungee cord.

Filling The Engine Bay

I have been saying for quite awhile that I cannot wait to get to the point where I am finally putting stuff back onto KITT. It seems like all we have done is strip the car down and I am ready to start putting things back together. I mean sure the sound deadening was something we put into the car, but it also was not something that was originally there.

Well, these last few days I started doing just that. I decided to install the front to rear fuel and brake lines yesterday. I started by getting out all the new brake and fuel line clips I had purchased and comparing them to the originals I had saved. There were some slight differences, but nothing that would really matter.

Wednesday, July 31, 2013

Another Night Of Waiting In The Garage

I stopped in at Troy's shop after work and confirmed that he was still coming over this evening to help install the rear end. He said he was and I double checked to see if he needed me to buy anything or get anything ready. He said "Nope, just be there". 

And be there I was. I waited all night out in the garage. I have lost track of how many nights I have done this now. (If only I had a blog that documented it...)

This afternoon, after I stopped at Troy's, I decided to apply Threadlocker Blue to the bolts Sara and I had torqued on the rear sway bar end link brackets this weekend. This involved removing the bolts one by one, cleaning them, applying the Threadlocker, and torquing them again.

Sunday, July 28, 2013


This afternoon Jonathan decided to go through some of the tubs in the garage and get out the parts we need to install the rear end. The first thing he found was the rear shocks. He decided to get them put into place so they are hanging and ready for installation.

More Birthday Surprises

We went to church and out for lunch today with our friends Jessica and Jake and they had a birthday gift for me. They gave me some really cool Pac-Man wind ups that have been on my wish list for a while, The Death of the Incredible Hulk movie and...

K.A.R.R from the Hot Wheels Retro Entertainment series. I have been searching for this for months! Thanks Jessica and Jake!

Saturday, July 27, 2013

Sound Deadening, Finally Finished (Kind Of)

I told Jonathan we could work on KITT all day long today, and that is what we did. 

Jonathan started this morning by test-fitting his new speakers. These are the 5.25 speakers that will go in the kick panel area. This is where the models equipped with the Bose stereo system had speakers mounted. The speaker magnet fits easily into the opening already in this area. We should not have to modify much to get these speakers to fit perfectly.

Friday, July 26, 2013

They Say It's My Birthday

Troy called this morning singing birthday greetings, and to tell me Farm Power Manufacturing had called him and said the mounting plates were ready to be picked up. Sara and I had brunch and then drove out to Farm Power Manufacturing to pick them up. The plates look like they will work great. These will be welded to the bottom bracket portion of the muffler clamp. The total came to $23, which is what I had expected, but the guy at Farm Power Manufacturing was quite surprised it cost that much. He said he thought it would have only cost a few bucks for the two little plates... which made Sara and I wonder just for a second if we were being ripped off. ;) My total cost to make both clamps was $32, which is a far cry less than the aftermarket ones that are available online for $100+. So no matter what, I think I did pretty good.

Thursday, July 25, 2013

Knight Designs Taillight Blackout

Here is the taillight blackout I have purchased for KITT.  Watch for an upcoming blog post when it comes time to install it.

Knight Designs

Project: K.I.T.T. has chosen Knight Designs for all of the Knight Rider related conversion parts needed for KITT.  Billy's parts are absolutely the best out there and I think this video sums up why.  I am going to be posting a few of his videos on the Blog just to highlight some of the wonderful parts that will be going on KITT in the near future.  If you have not already, be sure to visit his website at

Locating New Hardware

I had to go in to work early today and was off by 1:00PM, just in time to have lunch with Troy. We talked about some of the hardware I am going to need to replace, such as the rear sway bar mounts and the bolts for the A-arms.

I had done a little looking online for the rear sway bar mounts only to find them extremely overpriced, at least in my opinion. The stock ones were nothing more than a glorified U-bolt style muffler clamp with a mounting plate on the bottom. Troy made some calls and located a pair at Exhaust Pros that were the right size. I ran and picked them up and also grabbed my sway bar bushings so I could see what modifications we would need to make, if any.

As you can see in the picture below the clamp is about half the width of the busing, which means we will need to fabricate a mounting plate for the bottom. I took both parts to Farm Power Manufacturing to have two plates made to those specifications. Once we have the plates we will weld them to the bottom half of the clamp and we will have made new sway bar mounts for far less than any of the aftermarket ones.

Wednesday, July 24, 2013

Never Enough Pictures

Today I discovered that you can never have too many pictures. There have been many posts already where I have said, "I wish I would not have taken so many pictures; we really do not need all of them". Well, I am here to tell myself that yes, you probably do. 

I wanted to be prepared to reinstall KITT's rear end by making sure I had all the hardware ready to go. There are some things I just was not sure about, even though we marked and bagged everything. I figured the easiest way to figure it out would be to look for a reference picture from before we removed it. Guess what? I don't have a picture that shows the particular hardware I am looking for. Lucky for me I have the illustrated parts book for the car and could compare notes with that. So, just for the record, if anyone should attempt a project like this, make sure to go nuts with the camera. You cannot have too many pictures!

After finding most of the hardware I was looking for I decided to clean up the bolts a bit. I don't have a grinder with a wire wheel, but I do have a clamp for my drill that allows it to become a stationary wire wheel.

Monday, July 22, 2013

Sound Deadening, Part 9

I spent a little time this afternoon adding some more sound deadening to the transmission hump. There is a lot of noise in this area so I ended up doubling up a little.

Sunday, July 21, 2013

Fan-Created Knight Rider Video Game

This is awesome!  If you have not been following their progress, you need to check this out!

Saturday, July 20, 2013

Project: P.I.T.A.

Troy was stopping over this afternoon to help reinstall KITT's rear end. In preparation I started getting everything we would need ready. This included the Panhard/track bar brace that I had treated with Prep and Ready yesterday. I had let this soak all night and it had completely gelled this morning. Sara and I sprayed it out with water and it did remarkably well at removing the rusted corrosion inside. Unfortunately it still had a ways to go before it would accept the original 14mm bolt.

Troy called as I was pondering how to enlarge the metal sleeve in the brace. He wanted to let me know that he was running late due to a late appointment at the shop and he would be over as soon as he finished. I told him about the issue with the sleeve on the brace and he said to bring it down to the shop and he would use the die grinder on it.

Sara and I took it down to the shop and Troy was able to use the die grinder to restore the sleeve to its original size. He said that he would be finished here and stop over in about 45 minutes. That was at 1:30PM. Before I left I borrowed a 9/16 drill bit to enlarge the holes in the Panhard/track bar bracket. The original bolts were stepped down from 14mm to 12mm and as a result one hole was 14mm and the other side was 12mm. I could not find replacement bolts in this style so I went with 14mm bolts. I needed to enlarge the 12mm holes to 14mm. I figured I could work on this while I waited for Troy.

Painting The Subframe Connectors, Part 1

Friday after work Dad and I were on a mission to find replacement hardware for the Panhard/track bar, the Panhard/track bar brace, and the trailing arms/lower control arms. It took a bit of searching and a lot of running around, but we managed to find everything we needed. Thanks for your help Dad! Here is everything we bought.