Todd's 2003 Spyder GT (re)build thread

[todd.the.submariner]

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.

A further recommendation for keeping things in order, I kept my ipad handy and made a note at each step, including which bin each step's fasteners when into. That way you can just have bags labeled 1, 2, 3, etc... and your notes contain all the details to keep things in order.
For instrument cluster bulbs, in case you haven't already looked them up, note there are two different power levels, 2W and 1.2W. Red caps are 2W, black are 1.2W. 2W bulbs are in the pic posted earlier.

Enjoy your tool shopping!

 

[Black Mazerati]

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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I must say I'm a stickler for doing things the right way also. But! This is one alteration that I can't see any repercussions from doing. If it was just a trip down the street to exchange I could understand, but across the pond makes it frustrating. I will say I wouldn't do it if had to add a reducer or adapter. Believe it or not they do sell heater hose with an ID of 11/32 that would probably work.

 

[todd.the.submariner]

I must say I'm a stickler for doing things the right way also. But! This is one alteration that I can't see any repercussions from doing. If it was just a trip down the street to exchange I could understand, but across the pond makes it frustrating. I will say I wouldn't do it if had to add a reducer or adapter. Believe it or not they do sell heater hose with an ID of 11/32 that would probably work.

Tis a bit of a pain but not so bad for me. I live in Seattle, and Brassworks is a mere 1400 miles South near LA. Shipped off the core yesterday. Will take up some shipping time but in the meantime I’ll groom and clean all the removed components. Considering replacing the rather worn carpet now I have everything out of the way. Floor mats already on order, they were so brittle they crumbled on removal, from a life in the California sun no doubt. Also a new webbed elastic pocket for the rear wall as mine is sagging like… like something that spent two decades in the sun, I suppose.

When life hands you lemons, pull out the gin and vodka, it’s Vesper time.


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[Black Mazerati]

Tis a bit of a pain but not so bad for me. I live in Seattle, and Brassworks is a mere 1400 miles South near LA. Shipped off the core yesterday. Will take up some shipping time but in the meantime I’ll groom and clean all the removed components. Considering replacing the rather worn carpet now I have everything out of the way. Floor mats already on order, they were so brittle they crumbled on removal, from a life in the California sun no doubt. Also a new webbed elastic pocket for the rear wall as mine is sagging like… like something that spent two decades in the sun, I suppose.

When life hands you lemons, pull out the gin and vodka, it’s Vesper time.


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Hmmmm, Mine came out of England. Cheers but I will take a whiskey instead!

 

[DLax69]

Tis a bit of a pain but not so bad for me. I live in Seattle, and Brassworks is a mere 1400 miles South near LA. Shipped off the core yesterday. Will take up some shipping time but in the meantime I’ll groom and clean all the removed components. Considering replacing the rather worn carpet now I have everything out of the way. Floor mats already on order, they were so brittle they crumbled on removal, from a life in the California sun no doubt. Also a new webbed elastic pocket for the rear wall as mine is sagging like… like something that spent two decades in the sun, I suppose.

When life hands you lemons, pull out the gin and vodka, it’s Vesper time.


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...this right here is gonna be the problem. When I go in for the core, everything will get a bath and/or replacement...once I fall down a rabbit hole, I fall alllll the way down.

 

[todd.the.submariner]

...this right here is gonna be the problem. When I go in for the core, everything will get a bath and/or replacement...once I fall down a rabbit hole, I fall alllll the way down.

I was somewhat prepared - I had a list of things to fix while it is all apart, and pre ordered the requisite parts, but the list has now grown.


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[DLax69]

I was somewhat prepared - I had a list of things to fix while it is all apart, and pre ordered the requisite parts, but the list has now grown.


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...as it does.

 

[DLax69]

...my Brassworks unit is 3/4". Glad to know to check; hate to learn this way.

 

[todd.the.submariner]

Heater core replacement and interior reinstallation - complete!

Not many new lessons learned that aren’t covered extensively elsewhere. Just a few fasteners left out intentionally due to be well both impossible to reinstall. While the interior was apart, and as it’s winter so the car isn’t going to be driven anyhow, I fixed up about of little things, and now it feels so much more pleasant just to sit in the car.

Picture dump and notes to follow. Many of these are repeat pics from the “what did you do with your Maserati today?” Thread.

Steering wheel leather had separated from the airbag shell, all bubbled up. I left the leather attached by the center button but glued down the rest, securing it overnight with binder clips to the edge of the shell. Not perfect, but infinitely better!

Then polished up the steering wheel leather, bringing it back to life. Repeated this with all other leather interior parts.

Used alcohol and a terry cloth to clean all the sticky residue off the steering clamshell

While the instrument panel was out, replaced all 2W and 1.2W bulbs . The difference in illumination was striking, highly recommended!

Carpet was absolutely filthy. Used a carpet cleaning machine to shampoo it multiple times until clean

And voila! A refreshed interior! As well as a heater core that will likely outlast the car.

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[todd.the.submariner]

A few more interior fixes while disassembled. Added a cupholder to the drivers seat

And replaced the elastic pouch behind the seats.

Note the gap in the rear glove box. Attempted to address that but I think it’s due to the steel bracket to which the glove box is lifted. The brackets are both loose, but they are secured by screws that are quite a challenge to get to. I have a special extra short 90 degree screwdriver on order to fix it

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[Church of Noise]

Great improvements, and of the kind that you will notice every time you're in or around the car!

 

[DLax69]

Cupholder looks familiar. I tackled the storage when I did the fuel pumps...box had to come out, anyway...congrats!!

 

[todd.the.submariner]

Heater core replacement round two now complete. The Brassworks core was, quite surprisingly, not as solid as expected and let go the first time I got the engine up to temperature, soaking the carpets. Thankfully, the computer modules under the heater box are still working.

Removed all, replaced with an Alfa166 heater core that I had on hand, and all back together.

One problem, on disassembly, when moving the handbrake out of the way to pull the main dashboard out, I broke the handbrake switch that detects if the handbrake is engaged.

Learned a little about this switch in the process, as I initially just glued the two halves back together, but it failed to detect the brake being off. Took it apart and figured out how it works.

In the picture below, there are upper and lower contacts on the left, and a spring on the right. When the handbrake is released, it presses down on the spring and toggles the switch from the upper contact on the left to the lower contact on the left.

My contacts had been mashed together, so I simply pulled on the top contact to make a gap, and voila, electrical switching worked. Glued the halves together and installed, working as expected!

Why all the fuss over this little switch? Because it is no longer available to order!

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[Black Mazerati]

Man! That has got to suck! Have you reached out to brassworks? If so what did they say. Since this install is so fresh and unfortunately repetitive for you, How long does it take you to do it now?

 

[todd.the.submariner]

Man! That has got to suck! Have you reached out to brassworks? If so what did they say. Since this install is so fresh and unfortunately repetitive for you, How long does it take you to do it now?

I did reach out to Brassworks - they were professionally embarrassed. But you know… having been close to a lot of welding and brazing over the years, I know it happens.

Then sent me an RMA and a refund. Once I send the old unit back I’m not sure if they’re sending a new one for free, that wasn’t clear.

As for the install, lol, it’s become routine. About 4 hours end to end as long as the music is loud and not too cold in the garage.


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[Black Mazerati]

I did reach out to Brassworks - they were professionally embarrassed. But you know… having been close to a lot of welding and brazing over the years, I know it happens.

Then sent me an RMA and a refund. Once I send the old unit back I’m not sure if they’re sending a new one for free, that wasn’t clear.

As for the install, lol, it’s become routine. About 4 hours end to end as long as the music is loud and not too cold in the garage.


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I figured you would be quick at it but that's breakneck speed!

Sure hope that doesn't happed to someone that paid up for an install though I would feel bad either way!

 

[todd.the.submariner]

@Damichi

Remember the discussion about shifter sleeves last August up above in this thread? Well, the problem continues to be relevant as the printed version I have is not wearing well. Not sure entirely if it’s a poor model since they scanned my previous broken shifter sleeve and attempted to fill in the gaps, or the printer material isn’t up to the job.

Could you please scan what you have and share the model? I’ll work with a manufacturing engineer and will get some samples made and test them out on my Spyder, then share the results once we have a working alternative.

DM me here and let’s see what we can do .


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[todd.the.submariner]

Well, here we go for now. Had my Indy shop print out another shifter sleeve from the same material as an interim solution. Though, it’s cold and wet outside, so I’m going to go scan this new part myself so I have the file and can try out different materials for fun. Tempted to go with brass and be done with it!

Original part with broken end shown for comparison

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[DLax69]

Well, here we go for now. Had my Indy shop print out another shifter sleeve from the same material as an interim solution. Though, it’s cold and wet outside, so I’m going to go scan this new part myself so I have the file and can try out different materials for fun. Tempted to go with brass and be done with it!

Original part with broken end shown for comparison

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Liking the brass idea...

 

[todd.the.submariner]

Took her out for a short spin today as the rain let up for a bit. ohhhhh such fun, even just tooling around town.

The winter to do list is rounding down!

1. Finish the sticky removal
2. Heater core, when received from Brassworks. While the dash is apart:
- replace dashboard clock, mine is stopped.
- remove and re glue leather on the steering wheel airbag to remove bubbles
- Loud link Bluetooth install
- replace all instrument panel bulbs while it’s out
- install cup holder while seats are out
3. Fuel filler cap seal kit install to fix check engine light from vapor recovery system
4. Carpet and floor mat clean/repair/replace
5. Repaint rear bumper (some parking impacts)
6. Trunk lock inoperable
7. Rear glove box doesn’t shut properly (need to tighten support brackets inside the capote, very fun to reach)
8. Replace elastic pouch behind seats
9. Replace wheels, the stock wheels are just atrocious and painful to look at

Add two to the list:
10. Driver's side window stops when nearly up, then can be shut by inching it up incrementally. Not sure if the problem is in the door weatherstripping or the mechanism.
11. Long term solution to the gearshift lockout sleeve so I don't have to 3D print one every six months.

If anyone has a gearshift lockout sleeve in excellent condition, I'll gladly pay to have it 3D scanned, and of course comp you for your trouble. Would be beneficial to all of us to have a really good STL file scan of that part, then we can experiment with different materials to see what works best. The car is atrocious to drive with the sleeve worn down, and when broken, the entire gearshift assembly, disassembles itself in your hand.

Going to an indy body shop for an estimate on the bumper, and for kicks, an estimate for a complete redo of the paint job, as it has all the usual little nicks on the hood from highway driving, and some very minor door dings that bug me when washing the car.

Wheels. Tried talking a member here into shipping his gold 4200 wheels to me from the UK, but haven't heard back from him. Might have to go with the Formula Dynamics wheels if they'll give me a deal.

Window. Excellent weekend project to disassemble the door, get it all cleaned up on the inside, and see what we're dealing with.