944 Restoration

[eurocliff]

Hi again all,

Update to the restoration so far.......

Red Rooster received a pressy from Santa in the form of 4 new Hankook tyres (£390) from my Great Uncle Arnold (well that's what I told the other 'arf)

Currently, it's in a workshop for having the fuel pipes replaced in 8mm and 10mm copper as the originals look to be past their best. While at it, I'm replacing the clutch hose from the master cylinder to the hard pipe. I have tried the Goodridge replacement but, the connectors supplied are next to useless as they dont connect (2 sets bought) one off ebay and one from Merlin Sport. Resolution is OEM.

The rear calipers have been removed, disassembled, cleaned, painted and refurbed with new seals and refurbed pistons, capped off with stainless bleeders after reassembly. Rear brake discs replaced along with sensors and pads. Handbrake shoes have been replaced as the linings on the old ones were thinner than a brides nightie. All handbrake linkages and parts cleaned and unseized. New rear disc heatshields were sourced from Porsch-Apart along with new pipe brackets for the fuel lines. Don't know how these will hold the pipes yet though. original design brackets are no longer available but new plastic ones are.

The brake pipes are being renewed as required too with new terminators to attach the new brake lines to.

Unfortunately, no photos of this as yet but hopefully the workshop will allow me to take some when car is up on the ramp.

[troth944]

Hi Cliff,
I'm currently resurecting an '86 944 just over the hill from you in Paulsgrove.
I've currently got the entire intake system and camshaft box off chasing elusive vacuum leaks and the notorious cam tower drip in an effort to make my car run better and smell less like a burning chip shop under accelearation. Have you had your car long?

[kongsodoken]

Hurry up with the pictures

[eurocliff]

OK Kongsodoken, be patient Red rooster has had a bit of a setback. After looking at the emissions it would appear that the AFM is totally fcuk'd and it's chucking out more polutants than a leaking nuclear reactor. Fresh AFM has been sourced from Germany and fitted, will be hooked up to gas analyser on Monday and in for MOT on Tuesday if emissions are within limits.

The guys at SpeedyMech in Denmead have done a sterling job on the 944 replacing brake lines etc. Some were due to burst so, good timing on my part, methinks.

Photos will be forthcoming when I get the 944 back.

[eurocliff]

Restoration date 27 April 2012 and some piccies to wet your lips over...........

Right:

MOT passed with comment that the emissions although within parameters are on the upper limit. So we changed the AFM and discovered it wasn't that. Next was the removal of the injectors for a refurb by a local Bosch workshop who tested, backflushed, tested and replaced the seals, caps and spacers. Swiftly followed by the Fuel Pressure Regulator (FPR), it wasn't that either so the Idle Control Valve (ICV) was renewed together with the hose that goes from the ICV to the bottom spigot of the inlet manifold (this was replaced as after the new ICV was fitted it ran like a bag of nails and SpeedyMec discovered the old hose was perished). That said, it still didn't make any difference so I looked at the ECU and lo and behold I think I've found the culprit. Some mongrel of a previous owner has replaced the ECU with one from a 2.7L (944.618.121.06).

I am sourcing a 944.618.121.03 or 05 which are the proper ECU's that are for my model. I have asked on here but no news of any yet!

Red Rooster has now had a service comprising an oil change, new oil filter, new fuel filter, new brake and clutch fluid.

[eurocliff]

Just to further let you know that Red Rooster is now running just as it should. A proper ECU for the model and year was sourced from Warren at Porsch-Apart and duly fitted this morning shortly after its arrival. Together with all the other new bits it should be great.

Date: Description:
18-Aug-11 Dansk Exhaust (Complete)
19-Aug-11 Pop up Headlamp motor
20-Aug-11 Exhaust mounts
23-Aug-11 Anciliaries
26-Aug-11 Wipers
02-Sep-11 Anciliaries
22-Sep-11 Washer pump
26-Sep-11 Rear hatch lock
08-Oct-11 Door actuator rods
04-Nov-11 Rear cam oil seal
04-Nov-11 Track rod ends x2
09-Nov-11 Front brake fixings
09-Nov-11 Front Struts
10-Nov-11 horn low pitch
12-Nov-11 Front strut fixings
14-Nov-11 Anti roll bar bushes
14-Nov-11 Front Brake Pads
21-Nov-11 Caliper springs
22-Nov-11 Seal rings and sundries
25-Nov-11 horn high pitch
30-Nov-11 Front Brake disks
02-Dec-11 Fixings x6
17-Dec-11 O/S Door handle and lock
19-Dec-11 Caliper service kit
19-Dec-11 Caliper service kit
20-Dec-11 Tyres, track and balance
31-Dec-11 Handbrake shoes
13-Jan-12 Rear brake parts
27-Jan-12 Pipe clamps and Rear disk heat shields
28-Jan-12 Brake disks, pads and sensors
24-Feb-12 Air flow meter
08-Mar-12 DME Relay
12-Mar-12 Coolant Temp sensor
15-Mar-12 Injector seals
20-Mar-12 Injector service and test
30-Mar-12 Brake pipes, AFM, MOT etc
03-Apr-12 Fuel Pressure Regulator (FPR)
06-Apr-12 Castrol GTX Oil (2x5L)
12-Apr-12 Idle control Valve (ICV)
18-Apr-12 Hose, cotton reels and inlet MF gaskets
30-Apr-12 ECU 944.618.121.03


After taking it for a run, it was taken to Richard at Speedymech to hook up to the Gas Analyser and it returned wonderous results. So much so that we had to tweek them up to get it to optimum working in all parameters. CO2 levels are now at 2.00% with a lambda reading at around 1.01.

The sun has been switched on in celebration

Next is new seats that were sourced from a fellow TIPEC Member.

Will post up some more pics when fitted. Now, I'm going to have a bier or three.

[eurocliff]

Right, the saga continues..........

I managed to put the passenger seat in last night to get an idea of what it would look like.......FANTASTIC!!!!!!! I thought.

So, today I've re-commissioned the handbrake switch and that now works, installed the rest of the replacement seats (Old ones up for grabs if anyone's interested) and removed a cable that was for an aftermarket CD Multi-changer (not fitted). I was going to replace the radio/CD player but thought better of after looking at the spahetti behind the console. That's for another day!!!!

I've also discovered a wet patch on the rear driver's side footwell. Suspect it's the door seals that are the next item to be replaced.

I've added some more piccies.

[JW590]

That leak is more likely to be blocked sunroof drain tubes or sunroof seals.

[kongsodoken]

Looking good...you must be pleased

+1 for sun roof drains ...but if you do change the door seals the 968 ones are better IMHO

[eurocliff]

Red Rooster will be having its first public showing at the 'South Hants Vehicle Preservation Society's' Classic Vehicle Show to be held at Queen Elizabeth Country Park in Petersfield (literally, just off the A3). The date for this is set for May 27th 2012.

There is also an autojumble with a classic military and commercial vehicles on show.

New rear shock absorbers being fitted tomorrow (weather permitting).

*** UPDATE *** 12 May 2012.

Purchased a pair of KYB Gas adjust rear shocks. They don't fit although the supplier insists they are right for the car. This is true up to MY 1984 where the top and bottom fixings were M12 x 1.5 x 125mm bolts with associated nuts and washers (B12 and M12). But, from '84 Porsche changed the fixings. They kept the M12 x 1.5 x 125mm for the top eye and changed to M14 x 1.5 x 85 for the bottom eye, this screws into the rear axle carrier. It appears KYB have not taken this mod into account and still market the old spec as the new.

I've sourced a pair of original Sachs that will be at the supplier's on Monday. I'll take the bolts along just to make sure that all is ok.

[Althejazzman]

Bump. Still interested in reading this even if no comments are added.

[eurocliff]

Thanks for the advice on the sunroof Kongsodoken and JW590. I had to replace the sunroof cog wheel on the driver's side and this appears to have stopped the ingress of water. We've had a bit of heavy rain over the past couple of days and the floor is dry now where it wouldn't have been before.

Methinks I'll have a cuppa in quiet celebration

I've also made a new bracket for the low pitch horn and mounted the low and high pitch horns to their respective mounting points. A fifteen minute job I managed to eek out to over an hour.

Have a great weekend

[jmgarage]

Great progress, now the better weather (should) be here for a while, no excuse why you can't make excellent progress.. Keep the updates coming!

[dj.brian]

Now for sale in the "cars for sale" section.
A few too many £'s for me, but looks like a good one !