What have I done now....

[Rhett]

Hi guys, thanks all for the ideas, etc. I do not have a photo at the moment, as once I broke the drill and realised I couldn't get it out, I went in and got a cup of tea ...then it got dark!

The drill is a standard 5mm HSS bit. Presently sitting in a sleeve of what is left of the steel stud - boy, that thing is seized solid!

However, I have the rest of the drill on the bench, so I am going to experiment with some Dremel grinding tools, the sort that sharpen chain saws, or similar. Once I find something that will grind the 'bit', I will give it a go. I have not done a Helicoil repair myself, but even at my 'grand old age' I am willing to try and the kits are not too expensive.

Not willing to give up - as Gene Kranz once said - 'failure is not an option!'

[Rhett]

Ok, things have been busy recently, so not a lot to report. However, I have not yet had a go at the stud problem - hopefully I will soon..

Anyway, got out of the rain and into the garage the other day. Decided to start cleaning up the cam box, here a few before/after photos:

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cam belt cover 5.jpg (119.91 KiB) Viewed 16148 times

I think you can tell which is which... . Part needs a good degrease now.

[Rhett]

Then the cam box itself:

cam box 1.jpg (121.99 KiB) Viewed 16148 times

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cam box 6.jpg (119.86 KiB) Viewed 16148 times

A bit of corrosion...defo needs a clean!

[Rhett]

Here it is now..a bit better...

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cam box clean 5.jpg (146.13 KiB) Viewed 16147 times

cam box clean 6.jpg (103.03 KiB) Viewed 16147 times

It is a good start I think...on to the cylinder head next

[Rhett]

Too cold to be messing with the 924S on the drive ! However, thought I would have a go at fixing the large rubber seal that goes around the fuel filler pipe. This part is NLA from Porsche. Most breakers have them, but they are generally all in pretty bad shape. So, a fix was needed. Here is what it looked like to start with:

fuel pipe rubber seal 1.jpg (92.04 KiB) Viewed 16088 times

fuel pipe rubber seal 2.jpg (90.22 KiB) Viewed 16088 times

fuel pipe rubber seal 3.jpg (87.79 KiB) Viewed 16088 times

Quite badly cracked, so out with the superglue - brilliant stuff!

fuel pipe rubber seal 4.jpg (87.97 KiB) Viewed 16088 times

fuel pipe rubber seal 5.jpg (82.91 KiB) Viewed 16088 times

Now I need to fix the drain tube..so not finished just yet.

[hotblack944]

I've just bought a new one of these from Porsche for my 944 S2. Any tips for how to remove the old one?

[Rhett]

Hi Jim, the design is slightly different between the 924 and 944, but basically they should come out the same. First thing is to remove the filler cap and put a rag/tissue in the filler tube to stop 'stuff' falling in. Then remove the large spring clip that holds the filler 'flap' in place. Once this is out you should be able to deform the edge of the seal enough to bring it forward over the lip. The 944 doesn't have the same drain arrangement, so there is no pipe to disconnect. A little washing-up liquid on the filler tube should help you wiggle the seal off and out.

Good luck, I need to do this for my 944S too..

[hotblack944]

Thanks Rhett. I'll have a crack at this over the holidays.

[Rhett]

Well...haven't really had much of a chance to do anything to the 924S over the last few months. But...as it is getting a bit warmer, I think I might 'fiddle', or 'tinker' some more in the near future. I did however get some progress with the fuel filler gasket:

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image 2.jpg (79.36 KiB) Viewed 14680 times

I used black RTV sealant and some self-adhesive heat shrink.

Getting there

[944er]

Just stumbled across this thread - absolutely brilliant! Well done with all the work so far, and best of luck to you

[Rhett]

A nice dry and warmer day today, so time to do some more Porsche 924S dismantling! Decided I should remove all the fuel line components so I can fabricate some replacements, etc. Here is what it looked like - note the jubilee clip and rubber hose repair on the high pressure fuel feed line...this is not really recommended

fuel pipe 1.jpg (136.09 KiB) Viewed 14615 times

fuel pipe 2.jpg (131.01 KiB) Viewed 14615 times

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More to follow...

[Rhett]

Continued...

fuel pipe 5.jpg (118.04 KiB) Viewed 14613 times

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fuel pipe 7.jpg (125.35 KiB) Viewed 14613 times

Everything is now off. Looks like I will be making up some new pipes (possibly Kunifer like I did for the 944S), as well as braided rubber for around the pump and filter. I will also be dropping the gearbox and taking out the tank, as I don't like the look of the corrosion I have found...ho hum

Once all that was done, I had a cup of tea..., then started on dismantling the handbrake components. They were pretty rusted up:

handbrake 1.jpg (135.88 KiB) Viewed 14613 times

However, they are all off now...

[Rhett]

Then removed the NS drive shaft, as I had already removed the OS. What a pain those splined bolts are.. Anyway, its all off ready for a refurb. Then started to work on removing the trailing arms...crikey the corrosion in the spring plate to trailing arm bolt holes was immense. I ended up shearing off the heads of two 12mm hi-tensile bolts, as they just would not budge. However, I was using a humungous long breaker bar though . NS trailing arm is now off, came in for supper after dealing with some of the OS fixings....well, that's about it - tomorrow is another day!

[Rhett]

OS trailing arm is now off too - sheared off another two 12mm bolts... Those small (7mm?) bolts that hold on the brake disc cover are stupidly soft and well corroded into the alloy arms. So, two of those sheared off too. I was being very careful, heating them up, backing them off, but still they snapped... .

I have never busted so much stuff on any other car project, this one is being a bit of a pig . Never mind, I did kinda expect it.

[Pete82]

OS trailing arm is now off too - sheared off another two 12mm bolts... Those small (7mm?) bolts that hold on the brake disc cover are stupidly soft and well corroded into the alloy arms. So, two of those sheared off too. I was being very careful, heating them up, backing them off, but still they snapped... .

I have never busted so much stuff on any other car project, this one is being a bit of a pig . Never mind, I did kinda expect it.

Not making progress unless something breaks.

I hate it when manufacturers use the most stupidest weakest bolts that don't stand up to corrosion.