2014/06/17 Small steps

Some small stuff has been finished the last couple of days. Replacing the door lock was easy, but it has to be said it was only the outer part that was replaced. Putting the door trim back in place has become a routine job but it’s clear I’d better don’t take it off too much anymore. It’s not completely finished btw. since I lost a screw.

A lot of time got waisted reconnecting the electrical mirror. I had started with the right connections, luckily I’d found a pic on the internet with the connections, but it didn’t work. With a multi meter and the wiring diagram I’m trying to solve the problem with logic but after half a day I’m back with the original connections and an bottle of contact cleaner. That does the trick, it works.

Despite previous efforts, electrical problems keep appearing. I’ll have a look at the “electrical miracle shark” again. The multimeter remains close at hand.

Unfortunately I’ll have to dig into the CIS too. The shark isn’t idling nicely, a problem that appears more often so it seems when one has taken off various CIS componenten.

A daunting task…

2014/05/29 On the road again

“No Sir, it’s hard to say what the problem could be. We will have to open your gear box and only then we’ll know what’s wrong. A price you say Sir? No can do sir, this is according to the damage on your gear box. Opening and closing your gearbox will be around 1500$.”

I’ve solved the problem with replacing the rear coupler bushings. Thanx to the Rennlist forum I’ve stumbled across the subject of loosing certain gears and in most topics these bushings seemed to be the culprit. About a 10$ fix proves the “professional specialists” wrong.

At first it was idling nicely but after backing out of the garage it wasn’t the case anymore. A tube had come loose from the WUR but we’ve got reverse!

And we can engage first!

The HVAC problem is fixed, thanx Jim. The car isn’t smoking anymore so replacing the gaskets of the OAS and water bridge proved useful. 

All this (except the reverse problem) is the consequence of a plan to clean the groundpoints and fix some electrical issues. I haven’t cleaned a single groundpoint and not all electricity got fixed despite the fact that I did have a look at it all. The upcoming weeks I’ll deal with some of those again, along with replacing a door lock, fixing the oil pressure sender unit, fine tuning gear shifts and get out a bottle of injector cleaner and engine flush. But first I’ll enjoy some mileage.

2014/05/26 Rebuild

The rebuild starts with making a “reproduction” of the water bridge gaskets. I’m not sure we can tighten the screws to the specified torque so I prefer to make a “test set-up” without screwing with the new baskets.

I’ve taken a lot of pics during deconstruction and along with the WSM, Parts catalogue and my memory I’m able to figure out where everything was placed. Not easy, but I don’t have to worry about Alzheimer yet. 

Despite long hours on saturday, I’m unable to finish the rebuild but there’s some hope that monday will be the day. Unfortunately monday proves to be a “ we do not collaborate day”. Nuts and bolts get lost and only intense searching makes them resurface, everything I pick I drop again and some parts are mounted and then broken down again because they’re obstructing the construction of another part. :evil:

At the end of the day everything’s back on it’s spot except a fuel line gasket. It is by no means a coincidence that the last bolt is a PITA and get’s me on the brink of taking a hammer. The gasket has fallen almost out of reach on top of the V block. I have to remove a tube again and even then it takes another hour of “fishing” before I can get my hands on the bastard. I finally get my revenge and take out the hammer after launching a bottle of brake cleaner via the shortest route into the garden. :evil:

2014/05/19 Strictly commercial

After some more cleaning this is the “before and after” commercial.

2014/05/18 Santa

It seemed like Santa missed the right season this week. A big order of parts and gadgets from the Porsche classic line found it’s way to my doorstep and I didn’t even hang a christmas stocking. Unfortunately Santa doesn’t work so I head into garage armed with a Dremel, brake cleaner, refined petrol and acetone to do some cleaning.

The OAS, water bridge and parts of the CIS get a good treatment.

2014/05/09 Driving whitout movement

Today came the opportunity to put the car on a trailer and take it to a befriended old timer owner. I gladly take the chance to put the car on his grease pit and fix the rear coupler problem. The parts have been in my possession for a while and on paper it seems an easy job but then again, the water bridge fix seemed easy to. Getting the shark on the trailer takes a 50m, fatiguing push.

Fortunately the bolts let go easily this time and apart from the fact that it’s hard to reach, we’re done quickly. (Again, I didn’t do too much). It seems to be shifting (at feel) but I can’t start the since the parts for the water bridge haven’t arrived yet.

2014/04/27 I'm done breaking down

Before drilling out the remaining bolts, I remove the OAS. It’s dangling in my way, held there by a strange construction of Iron wire and a spring. The spring is attached to the throttle so I think when I restart the car the throttle might stay open, but I’ll deal with that when it happens. This construction is not to be found in the WSM so it’s probably an invention by the PO or another F.ck Up.

With the capable help of bolt terminator José and his assistant, Tom, the bolts are removed in a professional fashion and the holes get new screw thread. It’s a day with a lot of progress, probably because I didn’t do too much :-), and at the end of the day deconstruction is over. Rebuild will start soon but first I have to order some parts.