So.... it's been nearly 3 years since I've posted anything about actually turning an actual wrench on the DMC- but thankfully that changed this last weekend. Partially out of frustration that I'd not gotten anything done in such a long time and partially out of the desire to eek a bit more usable space out of the garage to stage things for the upcoming annual yard sale for The Dancer's non-profit, I intended to get started on pulling the rear suspension so the stripped frame would be a bit wider. But... in looking at things, I realized that it would make more sense to pull the engine first so I could get to the transaxle and driveshafts more easily. So I set about doing that.
The first day I worked on it, it was raining on and off so I had a problem- The Bat really wanted to be outside since I was, but she couldn't just lay out on her blanket in the yard because of the rain and didn't want to be all the way on the deck. So I dragged her yard blanket (an old moving blanket) just inside the garage door where it was dry- and to my great delight (The Dog was not a shop dog at all- he wasn't nearly as fond of being outside as she is) she happily plopped down on the blanket to chew on a stick.
First up was pulling the belts, alternator, starter, and the carb/intake manifold. This went pretty smoothly since most of the bolts involved were going into the block and were stainless.
Removed carb/intake manifold assembly. This has been one of the more unique features of my DMC compared to a stock one- a stock DMC's PRV has a K-Jet mechanical fuel injection system, which when kept maintained does work well. But if it gets out of whack (which can happen easily) it can be a pain to fix and so few engines ever used it before electronic fuel injection became the norm that I decided it wasn't worth the cost or hassle and bought the carb manifold from a guy who made a short run of them.
Pulled the exhaust manifolds and had to wrestle with the motor mounts (to not pull the transaxle at the same time you have to unbolt the mounts from the frame and not just the engine from the mounts since it has to slide back off the pins on the bell housing- thankfully when I put in the new mounts I also used stainless bolts so they came out easily, it just took a while since there's very little room to rotate a wrench on them), but got the engine free and the hoist attached.
Engine free and out of the engine bay. The very back crossmember on the frame will be getting cut out eventually and replaced, likely with an aluminum channel that will be bolted to the frame. This will make access back there a lot easier (not that it will be as much of an issue if, as I plan, I go with the electric conversion).
Engine finally down on the cart. Took a bit of creativity to get it to sit solidly on it since the cart is built for a Chevy V8, but it works. It's now strapped down securely and tucked away under the body for the moment- I haven't decided exactly what I'm going to do with it yet, but for now it is out of the way.
I'm a bit town on the next step. I'm leaning toward pulling the transaxle next, since doing so will give me the chance to see just how much custom work is going to be needed to fit the Leaf drivetrain and connect it up to the DMC's axles. I've been trying to find info on how the DMC that was converted to use a Lead drivetrain did it, but so far haven't gotten an answer. I'm not sure whether custom axles will be necessary, or if it's possible to modify the Leaf axle connections to mate up. It looks like the DMC's axles go further inboard than the Leaf's did, but I've not directly measured that yet.
But- at least it's moving forward (the project, the car is obviously still not going to move for quite a while). Hopefully I can keep things moving. I really want to get the frame stripped down, the rust repaired and any mods necessary for the conversion done, and get figured out what exaclty I'm going to do in the way of a rust protection on it going forward nailed down before this next winter.