Porsche Enthusiasts Club Forum

Thank you gents Comments much appreciated

I feel like Pharell Williams.... "I'm so Happy"

Success of successes the gearbox is in

Transmission carrier was the first item to be reinstalled on the 'box







Then it was a case of using various techniques to get the 'box up in the air.... no idea how garages get these jobs done without a load of bricks and a couple lengths of decking boards

It needs to go up a long way!




First I needed to get some room underneath the 'box







Then the long decking board between the two trolley jacks just at the right centre of gravity so the 'box would raise without tipping one way or the other






and then higher and higher until the carrier was in line with the bolt holes to attach it to the body








I also started to fit fuel pump and filter onto the various bits of tinware.... Fortunately the terminals on the fuel pump are different sizes so you cant get them mixed up!





All connected but I cant for the life of me work out how the filter housing attaches to the car.... I did take a couple of pics of it before I took it off the car but I cant figure out the orientation.... any ideas or photos of its location are welcome

Today saw the final fitting of the gearbox ancillaries, connections and atf lines... so it's all in and connected....

Next on the list were the fuel lines themselves... the very things that started this madness in the first place! PITA doesn't begin to describe the layout of the lines under the car especially into the rear where they separate off to meet filter, tank, etc.

The new Porsche clips and rubbers don't really work that well given they are longer than the originals and have an elongated 4th hole for two pipes instead of just the one. This allows some undesirable movement...

Sorted it in the end though... Could we be starting the car up tomorrow? Hopefully as I stocked up on 3 Jerry Cans of fuel!

This bolt is only just reachable by hand... No sockets or spanners would reach until it was almost tight....



Sockets on the rear of the 'box above the atf reservoir is equally inaccessible...



After some fettling it's on and tightened up...



New lines connected to fuel rail - low pressure return on the left, high pressure feed on the right



Front wheel arch... Lines need to be fed behind the brake lines which isn't easy without some gentle persuasion!



At the rear, low pressure return in and connected... Just need to sort out the mele around the brake pipe splitter...



Looks simple but the overlapping at the front doesn't look right...



It's wrong!!! The gold high pressure needs to be above the black low pressure... damn...



Rubbers fitted ready for plastic clips. Note to any one doing this, fit all the rubbers before fixing the plastic clips or you won't have enough leverage to fit the other rubbers... Learned the hard way on this one!

looking good fella!

I found the new style line clamps a bit rubbish too

Brian

Thanks Brian I though I was going mad at first with those clips!

Yesterday saw a little more progress although I appear to have mislaid the flexi fuel line from the filter to the hard line which is a major PITA indeed.

Still we made progress

First job was to replace the foam rubbers between the tank and the tank/ pump guard - got these on the bay 20mmx3mm





Next was to reinstall the pump with the circlip positioned so that the screw mechanism is hidden down the side. Its not cosmetic, if its as I first did it here, it will foul the fuel tank and potentially rub on it over time....



So I moved it round to the side a touch...



With the pump in place on the tank, the cover plate was fitted using new clips and self tappers.



Filter came next - the bracket fits into the gearbox carrier but my aftermarket rubber bobbins had threads that were too long and could foul the body or fuel lines above it - so these were cut off...



Filter in place and connected to the pump....



Brackets around the torque tube then went on which also seats the rubber mount for the AT cooler lines





Final job yesterday was to sort the sheared bolt on the rear heat shield mount... This was the top of the bolt and it was well and truly corroded to the flange it sits on.



Various sizes of drill bit later...



...and we have one heat shield back in place



Torsion tube is going back in today - handbrake cable is the first job to reconnect and also to repair my previous butchery of the connector where it enters the car. More later!

Great work especially considering you're working on your drive.

Many thanks Matt The driveway mechanics haven't been easy mainly when the weather has been bad..... hopefully, a couple more dry days should see it done

I pick up my brand new (last one in the UK) filter to hard line flexible pipe on Saturday from OPC Bolton so there's a fighting chance she will make it to Le Mans on the 6th of July after all!

This afternoon saw an almighty fight with the rear beam - my God that's a heavy beast to wield around on your own!

First thing was how to get it under the car as I can't get the car any higher with my kit.....


Went in from the back of the car with one side through the exhaust cutout and then across to the right once under for swing the other end round and under the arch.... That was PITA number 1


PITA number 2 arrived in getting the bar off the floor and raised up into the recesses at each end.... first off, bottle jack in the centre




Then a block of wood under each end on a trolley jack




Until we get here - close but no cigar! The NS one is elongated but the OS is just round and here its a gnats whisker away but the bolt wont go in!




A bit of wiggling later and they're aligned but only where the bolt goes in - not where the bolt comes through! Here is PITA number 3. The rear swing arms are pulling down on the torsion beam assembly taking the bolt holes out of alignment so the hubs needed lifting with the help of my decking board and bottle jack.....


With this contraption, the holes are aligned and the bolts slide in perfectly






Final fixings on the torsion beam will be done in the next half an hour and then its handbrake cables, shoes and discs next along with brake lines. If I get calipers on and brakes bled today I'll be even happier!

So to finish off for today was a load of stuff you cant really see.... but it largely centred around this little lot



Fixing the spring plate mounts and shocks in place.... BTW, getting the NS shock into position at the top was a right royal PITA of the highest order!!!!


Fitting brake lines and cables to each hub...


along with bits that hold the skirts in place....


Although I needed to deal with the sheared bolt on the NS.... drilled out in the end...




Overall, shes starting to look like a car again

Today saw some progress in between (and lastly during) various rain showers but progress is progress which started with taking Martins advice and putting the old nuts back on the spring plate mount.

Then added some more new bling on the clips for the flexi lines - these were only £3.89 for 4 off the bay at http://www.ebay.co.uk/itm/221384069804?_trksid=p2057872.m2749.l2649&ssPageName=STRK%3AMEBIDX%3AIT


While I'm at it, these brakle clips that afix the two pipes against the rear bulkhead near where my rusty hole was are only £5.75 for three http://www.ebay.co.uk/itm/221751760746?_trksid=p2057872.m2749.l2649&ssPageName=STRK%3AMEBIDX%3AIT

After whichy we get to this


and hey presto a very cleaned up disc can go back on


then calliper and pads...


and the other side.... oh this is starting to really look like a car again


CV joints to the gearbox next but God knows why I bought 80mm bolts but I did and they are far too long so the old ones are back in for the minute.... at least until the new ones arrive tomorrow or Monday fomr my best source Eddie Bay http://www.ebay.co.uk/itm/181856392919?_trksid=p2057872.m2749.l2649&ssPageName=STRK%3AMEBIDX%3AIT


It rained on me whilst I was under the car on the CV joints, I was mainly OK but the legs got soaked!


It cleared up a bit and the inside of the car got attention on the handbrake. All in and done, 3 clicks and there's a firm handbrake.


Another new purchase was added with the switch http://www.ebay.co.uk/itm/281950895062?_trksid=p2057872.m2749.l2649&ssPageName=STRK%3AMEBIDX%3AIT


the reparation of my BFI removal of the handbrake cable was sorted by contact adhesive and a proper good pull on the handbrake level pulling the damaged end into the housing..... That's not coming out again!


Last thing was going to be to refit the seat belt and seat but the seat belt bolt is covered in all kinds of gunk - the stuff used on the carpets I think.... any ideas on something to remove it?


At last, the jobs list fits onto the kitchen wipe board Have I missed anything?

36lb/f for the cv bolts Chris

But looking good, but I would have painted those disks

OCD me

Thanks Martin

Ordinarily I would have painted them but time is against me.... although that might be a moot point given the fuel line hasn't arrived at Bolton the Le Mans dream could be over

So for now the rain has stopped play

CV Bolts should be here on Monday and OPC should have my fuel line on Tuesday so those jobs will have to wait. Car is now booked in for MoT at 8am on Wednesday morning so the deadline is now set. That gives me 5 days of tinkering time if its needed.

So far today, the exhaust has been fixed and fitted, just the tail pipe trim to go on now.

Angle grinder with twisted wire on it soon saw of the surface muck/ corrosion ready for the repair...







The gap is quite wide (even then the exhaust wasn't blowing at all but I just wanted to address the issue as far as I could at this time. The gap hammered in nicely and closed just enough for the repair bandage



Cleaned up the ends where the tail trim clamps on the exhaust and polished up the trim although a bit more to do on that before its refitted.







Rubbers and mounts then went on and then into position under the car - used my creeper which made it so much easier





More gratuitous use of trolley jacks and lifting the exhaust is a doddle







Centre section next and yes, trolley jack to the rescue again - so much easier than lifting by hand





Getting the bolts in was a nightmare for the top ones - I need much smaller hands! Ended up using a pair of long nose pliers to hold the nut in place whilst just about turning the bolt to get a single thread into the but... PITA! Getting this photo was almost as tough!



Sorted though now and I didn't forget to replace the O-Ring in the centre either



Drilled the crap out from the centre of the clamp and it threw it down.... M8x70 is going back in there afterwards....



The rain may now have stopped.... shall return!

I took Sunday off and had a round of golf at Mere - very pleasant afternoon

Got back to it this evening though....

Exhaust tip is now on and nice and shiny...





Seats are all back in and the gear selector back in one piece again....





Last two clips went in on the fuel lines in the front wheel arch



Then the liner went on



Wheels next - original 16"..... she's looking like a car again





Last thing tonight was the three drive plate bolts - and its a bu**er to turn!!



This very last one wasnt quite lined up perfectly to some prising of the drive plate was needed with a pry bar to give it just enough for the bolt to go in straight....



The check list is now being checked off



The only jobs left now for the MoT are:

CV Bolts - should arrive Tuesday
Flexi fuel pipe - collect from OPC Bolton on Tuesday
Check fuel line connections from end to end
Top up Power Steering fluid
Refill with fuel
Check lights, wipers, etc
Start her up

There is a fighting chance she could be ready for MoT at 8:00am on Wednesday morning and may just get me to Le Mans on the 6th of July.... wish me luck

your work rate puts me to shame!

im on my second attempt at trying to put a new handbrake cable together and failing miserably!

having another go tomorrow morning before the kids finish up with school for the summer

you dont fancy a working holiday up north........

your car is looking seriously excellent

I have to echo shep - damn that came together fast! I need some of your motivation

Looking good!

You need to book some tickets to the Le Mans Classic in 2 days time then!

Saying that My Turbo has been sat in the garage for 4 years now so I fall in to the latter category as well.

I have some stuff called Tardis at home that will get the glue and stuff off that seat belt bolt Chris. Not sure if you'll have it sorted by the time I see you next though.