Todd's 2003 Spyder GT (re)build thread

[todd.the.submariner]

Parts are arriving and piling up on my workbench, portending a busy winter in the garage.

First to arrive, the precious, no longer available, fuel filler cap gasket/valve that causes a CEL vapor recovery system fault. Many thanks to @Navcorr for the hookup!

In other news, the Brassworks heater core (or, matrix, as right-pondians say) arrived today.


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[DLax69]

Parts are arriving and piling up on my workbench, portending a busy winter in the garage.

First to arrive, the precious, no longer available, fuel filled cap gasket/valve that causes a CEL vapor recovery system fault. Many thanks to @Navcorr for the hookup!

In other news, the Brassworks heater core (or, matrix, as right-pondians say) arrived today.


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...my replacement replacement core is under a table in the living room, so...

 

[todd.the.submariner]

...my replacement replacement core is under a table in the living room, so...

Let’s pick a long weekend and do it at the same time! Advise an old tackle box for keeping the many fasteners stored in step by step order.

 

[CatmanV2]

C

 

[todd.the.submariner]

@CatmanV2 you may be on to something there. I was making good time, but seem to have encountered… complications.

Started the heater core (or matrix) replacement! Disassembly was mostly smooth, using the handy SM guide from years ago. I made note of the few differences for a Spyder, and perhaps the year of the car, but mostly self explanatory and obvious with a bright enough light.

Thank heaven for impact drivers to remove those dastardly screws on the box behind the passenger airbag. I remember stripping them on my Coupe, so was far more careful this time around.

Fully disassembled! But only one problem, the Brassworks handmade heater core has the wrong sized hose connections, and they are closed until 02 January.

So, using this time to do other work on the removed parts.

Replaced bulbs in the instrument cluster just because

Cleaned up the stickiness on the steering housing, headlamp switch, mirror switch.

Glued the leather on to the steering wheel airbag to remove the ugly bubbles look it had taken on.

And am cleaning up all the removed parts before reassembly… assuming satisfactory resolution to the heater core size debacle. Just in case, I ordered a Nissen Alfa 166 unit as a backup plan. Hate to do all this work to install a known bad part but it should last another dozen years or so.


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[Black Mazerati]

Man it's painful to see how far down you have to go to replace the matrix.

I don't think I would worry too much about the size of the connections. It's an easy work around and shouldn't effect the operation of the heater. If you need me to, I can dig mine out and measure the size of the connections on mine. It was advertised as a direct replacement for mine. I bought mine a little over 2 years ago.

Edit to add: I would be willing to wager new hoses that haven't been stretched would clamp and seal with no issues. Hoses can usually be made to work a notch up or down in size.

 

[todd.the.submariner]

Man it's painful to see how far down you have to go to replace the matrix.

I don't think I would worry too much about the size of the connections. It's an easy work around and shouldn't effect the operation of the heater. If you need me to, I can dig mine out and measure the size of the connections on mine. It was advertised as a direct replacement for mine. I bought mine a little over 2 years ago.

Edit to add: I would be willing to wager new hoses that haven't been stretched would clamp and seal with no issues. Hoses can usually be made to work a notch up or down in size.

@Black Mazerati
Thanks for the offer, but no need to dig out your heater core. I know this one was built incorrectly. I did this same job back in 2019 on my Coupe', and remember the tight fit of the heater hoses on reassembly. these hose connections, when measured, are several mm smaller. At least 1/8 " and the hose connections can't make up for that much of a gap. Hoping to be able to sort it out with Brassworks next week. Or, if not, I'll install the cheap Alfa 166 part and assume it'll last another 15-20 years.

 

[Black Mazerati]

@Black Mazerati
Thanks for the offer, but no need to dig out your heater core. I know this one was built incorrectly. I did this same job back in 2019 on my Coupe', and remember the tight fit of the heater hoses on reassembly. these hose connections, when measured, are several mm smaller. At least 1/8 " and the hose connections can't make up for that much of a gap. Hoping to be able to sort it out with Brassworks next week. Or, if not, I'll install the cheap Alfa 166 part and assume it'll last another 15-20 years.

That suxs. I'm going to go measure mine anyway!

 

[Black Mazerati]

Mine looks the same as yours from the pictures. ID is 17mm and OD is 20mm not including the flare.

 

[Nibby]

Good work Todd.
How big was the leak in the heater matrix?

 

[Gp79]

Good work, I remember the Alfa 166 one I fitted had slightly smaller connections but still worked out ok

 

[todd.the.submariner]

Good work Todd.
How big was the leak in the heater matrix?

Mine hadn't failed all the way yet, just a very small amount of weeping from the bottom corner on the end with the hose connections. I was replacing it out of an abundance of caution more than a dire need. Thankfully timed all this for the dead of winter, so I'm not missing top-down weather.

 

[todd.the.submariner]

Mine looks the same as yours from the pictures. ID is 17mm and OD is 20mm not including the flare.

Measured mine and the old one is 20mm outer diameter, Brassworks is 17mm OD. The hose visible rattles around it when mounted to a 3/4" standard hose.

 

[Black Mazerati]

Measured mine and the old one is 20mm outer diameter, Brassworks is 17mm OD. The hose visible rattles around it when mounted to a 3/4" standard hose.

Can you get 5/8" hose to fit on the other ends? I would go nuts leaving a job like your doing sitting like that!

 

[aawil]

I'm getting close to tearing mine down as well. I ordered the alfa part, just waiting for it to come in.

 

[todd.the.submariner]

I'm getting close to tearing mine down as well. I ordered the alfa part, just waiting for it to come in.

A few special tools to make sure you have on hand before starting (in addition to all the usual screwdrivers, hex wrenches and sockets)
Trim pullers
Impact wrench (pneumatic or electric) with Phillips head. Hammer driven one did nothing for me.
Offset screwdriver
Headlamp and/or glove lights
Secure torx bits (hollow center)
Very skinny 7mm box end wrench
Tackle box for sorting fasteners (about 30 bins needed)
-will update this if I think of more


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[DLax69]

Can you get 5/8" hose to fit on the other ends? I would go nuts leaving a job like your doing sitting like that!

...suppose, alternately, that a reducing nipple could work.

 

[todd.the.submariner]

...suppose, alternately, that a reducing nipple could work.

You know me too well, Dennis, we Sailors, when presented with having to stay late and do it right, or jury rig it now, will head to the latter choice without fail. I thought of it, but then thought of how I’d know that was at my feet on every drive.
Challenging as it is, in trying to get this Spyder back together to be as fit and ready as reasonably feasible. Waiting a few weeks to sort out what happened with the very expensive, hand built heater core… doable, though my Sailor side is wincing.


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[DLax69]

You know me too well, Dennis, we Sailors, when presented with having to stay late and do it right, or jury rig it now, will head to the latter choice without fail. I thought of it, but then thought of how I’d know that was at my feet on every drive.
Challenging as it is, in trying to get this Spyder back together to be as fit and ready as reasonably feasible. Waiting a few weeks to sort out what happened with the very expensive, hand built heater core… doable, though my Sailor side is wincing.


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...at least you wouldn't be on a dive. But yeah, it sucks. Still gotta dig mine out and measure...

 

[aawil]

A few special tools to make sure you have on hand before starting (in addition to all the usual screwdrivers, hex wrenches and sockets)
Trim pullers
Impact wrench (pneumatic or electric) with Phillips head. Hammer driven one did nothing for me.
Offset screwdriver
Headlamp and/or glove lights
Secure torx bits (hollow center)
Very skinny 7mm box end wrench
Tackle box for sorting fasteners (about 30 bins needed)
-will update this if I think of more


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I definitely need to pick up some offset screwdrivers, would have come in handy when I changed the instrument cluster bulbs. I'm thinking about using sandwich bags for the bolts and labeling them with a marker.