Hi John.
I must add, that this oil line fix was extremely gratifying. It is almost surreal how the dent gradually disappears before your eyes as you circle the torch around it!

Iv been pondering on your questions about strut tube and stub axle.
It is possible that there is a localized dent in the tube.
It is also possible the stub axle press fit over the tube has stretched ever so slightly.
In fact, we had to press the stub axle 0.5deg past the intended final position to account for that amount of spring back once the pressure was released in the press.

Perhaps Iv been over eager to see this issue resolved.
In order to avoid any future doubts, I’ll recheck the straightness of the strut tube.
I’m thinking of placing it between centers and reinspecting it for any runout.
If the tube is rotating true ( ie it’s not bent) then everything is fine, right?

Any localized small dent is negligible since it doesn’t affect the sliding fit of the damper insert inside the strut, right?

And the addition of “RSR STYLE” gussets will ensure that the stub axle stays securely in its correct place, even if the press fit collar is slightly more loose than originally intended.

The strut tubes aren’t particularly thick, or tough. I’ve come across stock, non race vehicles which showed signs of spindle defection on the tube. Your gussets should do the trick.

Good thread!

Thank you Jim

So, I setup each strut in a makeshift arrangement “between centres” and placed the dial gauge with magnetic base to crudely inspect and compare any runout in the LH and RH strut tubes;

http://forums.pelicanparts.com/uploa...1538067378.jpg
http://forums.pelicanparts.com/uploa...1538067378.jpg

• This (albeit crude) arrangement provided surprisingly stable/repeatable results.
  On the LH strut (the good one) I measured a runout of 0.5mm
  On the RH strut (the repaired one) I measured a runout of 1mm
  
  
• Contrary to what one would assume, the mounting hole for the lower ball joint is not concentric with the strut!
  The "wobble", as indicated by the red centreline, was clearly visible as I rotated the struts.

http://forums.pelicanparts.com/uploa...1538068921.jpg

All in all, I’m quite happy with the repair and happy that the strut tube isn’t bent.
Next step, to add the “RSR style” gussets ;)

Good stuff.

Nice work matey!!

Thank you John

Thank you Spencer

External Oil Thermostat Housing (continued)
 

So i've been trying to loosen the 38mm cover. My mate Brenton helped me out by turning a "coin" for me to the exact sizes required (Dia 37mm x 3.8mm Thk):

http://forums.pelicanparts.com/uploa...1538503828.jpg
http://forums.pelicanparts.com/uploa...1538503828.jpg
http://forums.pelicanparts.com/uploa...1538503828.jpg

I thought mild steel should be more than strong enough....after all, it is indexing into an Alu slot!

Take 1: :rolleyes:

http://forums.pelicanparts.com/uploa...1538504126.jpg
http://forums.pelicanparts.com/uploa...1538504126.jpg

hmmm....I halted before causing damage to the Alu slot.

Take 2: :rolleyes:
Subsequently, Take 2 was repeated with assistance from my father in-law.
He applied the torque on the wrench after I applied heat to the housing via Mapp gas torch + a few healthy smacks to the coin with a hammer.
Equal fail....hence the frustration and omission to take more photos.

Busy rethinking the approach...to be continued!

TIG Welding Practice Practice Practice
 

In preparation for welding the “RSR style” gussets, I need to practice running some beads on 3mm plate. (I am leaning towards using 3mm plate for the gussets)
This is also an opportunity to try out my new welding helmet with jumbo viewing lens :D

http://forums.pelicanparts.com/uploa...1538505804.jpg

Dremel setup with diamond wheel used to grind my tungsten

http://forums.pelicanparts.com/uploa...1538505804.jpg

1st and 2nd weld that I put down (both @ 130amps).
Far from #weldporn but pretty ok for amateur DIY! :cool:
In hind sight, I omitted to brush the scale off the plates before welding.
This caused some splatter contamination on the surface of the welds.
Otherwise, the penetration and heat affected area looks ok.

http://forums.pelicanparts.com/uploa...1538505918.jpg

Pic of the back of the plate, showing a nice and narrow heat affected area.

http://forums.pelicanparts.com/uploa...1538506135.jpg

Need more practice practice practice...

Spring Plate Disassembly
 

Here is another pic of the work in progress on the 930...in good company with the Cafe 9 Automotive 935 :D

http://forums.pelicanparts.com/uploa...1538927219.jpg

Well…while I’m in there, might as well do some cosmetic freshening ups!

Spring plate disassembly - Take 1:

http://forums.pelicanparts.com/uploa...1538927219.jpg

Nothing kills your enthusiasm (and ego) as quickly as a complete failure on executing what you initially considered to be a trivial exercise!
My failed attempt to disassemble the spring plate clamping bolt and adjustment bolt left feeling quite “humble”. My pneumatic impact driver made ZERO progress.

Spring plate disassembly - Take 2:
Take 2 was repeated with assistance from my father in-law.
He held the spanner on the bolt head while I applied heat to the nut via the Mapp gas torch.
Once hot enough (boiling spit test), I attacked it again with the impact driver.
Still ZERO progress. Darn, I didn’t even need to restrain the bolt head, it didn’t even come close to rotating.

Time to retreat and read up on the subject in order to plan the next step.


Spring plate disassembly - Take 3:

After a quick pelican search on the topic, I learnt that these bolts are torqued at approx. 250Nm.
I also gathered that they you need a hefty power bar and you need to put your weight into it to break them loose.
My mate Brenton came to the rescue and lent me a power bar and some more hex sockets (24 & 36).

(...Oh, Brenton also lent me his Ingersoll Rand impact wrench as a backup (more about that in a moment)

This time I didn’t have a second pair of hands. So, I set everything up in the vice for a solo attempt.
The spring plates were placed on the bench with the nuts inboard and the bolt heads outboard.

The power bar was placed on the nut (inner side). I supported the socket with a make shift “v-block”, to keep the engagement nice and square on the nut, while I tug on the end.

My T-handle with power bar extension was placed on the bolt head (outer side).

Long story short – I tugged on the power bar and nothing. I added another pipe/extension for more leverage and tugged again….still nothing , but after witnessing the amount of flex on the power bar I aborted that approach.

Spring plate disassembly - Take 4 (The One with the Big Guns):

Time to call the Big (impact) Guns. My hopes turned to Brenton’s IR impact wrench.

For future reference, the vital Technical Specifications of the Ingersoll Rand 2135PTiMAX Series Impact Wrench - Nut-Busting Torque (1100 FT-LBS / 1490 NM) :eek: !!!

http://forums.pelicanparts.com/uploa...1538932217.jpg
http://forums.pelicanparts.com/uploa...1538932217.jpg
http://forums.pelicanparts.com/uploa...1538932217.jpg

WOW WOW WOW. This impact wrench is a BEAST! #peaceofcake #doesnt_bat_an_eyelid
It is difficult to explain it in words, you need to witness it working to understand.
Just the knocking sound it makes (compared to my mickey-mouse impact wrench) means business!

Spring Plate Disassembly
 

http://forums.pelicanparts.com/uploa...1538932707.jpg
http://forums.pelicanparts.com/uploa...1538932707.jpg

There you have it folks......not all impact wrenches are made the same.
You get what you pay for!

http://forums.pelicanparts.com/uploa...1538932707.jpg
http://forums.pelicanparts.com/uploa...1538932707.jpg

Preparation of Suspension Parts for Replating
 

Well…while I’m in there, might as well do some cosmetic freshening ups!

After the application of a variety of power tools with steel brushes ...voila!

http://forums.pelicanparts.com/uploa...1538933846.jpg
http://forums.pelicanparts.com/uploa...1538933846.jpg
http://forums.pelicanparts.com/uploa...1538933846.jpg
http://forums.pelicanparts.com/uploa...1538933846.jpg
http://forums.pelicanparts.com/uploa...1538933846.jpg


http://forums.pelicanparts.com/uploa...1538933846.jpg
http://forums.pelicanparts.com/uploa...1538933846.jpg
http://forums.pelicanparts.com/uploa...1538933846.jpg
http://forums.pelicanparts.com/uploa...1538933846.jpg
http://forums.pelicanparts.com/uploa...1538933846.jpg

Making good progress to get everything prepared and ready for replating.

Costa, I will renovate my SC suspension this coming winter and keep thinking this would be a cool bit of mission-creep:

http://forums.pelicanparts.com/porsche-911-technical-forum/432703-modding-factory-spring-plates.html

One could of course just buy Elephant's elegant solution but clearly you have the skills and gear to do this all by yourself. Best, John

MUST. RESIST.
😂
John! Stop encouraging my urge, to dive head first, down the slippery slope!

Take 3 - succeeded!
Iv documented the successful tool here:
http://forums.pelicanparts.com/porsche-911-technical-forum/1010620-diy-tool-external-oil-thermostat-cap.html#post10219008

Suspension parts refresh and Zinc plating (continued)
 

It has been a while since my last update. In the meantime, I’ve slowly been completing various tasks and the results are coming to fruition.


http://forums.pelicanparts.com/uploa...1541877591.jpg

http://forums.pelicanparts.com/uploa...1541881515.jpg


Iv posted a detailed writup with lots of pics in the 911 Technical Forum
http://forums.pelicanparts.com/porsche-911-technical-forum/1012754-suspension-parts-refresh-zinc-plating-continued.html

DIY fabrication of RSR style gussets for Bilstein struts
 

Spoiler alert!
The RSR style gussets turned out awesome :D

http://forums.pelicanparts.com/uploa...1541886656.jpg[/QUOTE]

I submitted a detailed write up with pictures in the 911 Technical Forum
http://forums.pelicanparts.com/porsche-911-technical-forum/1012772-diy-fabrication-rsr-style-gussets-bilstein-struts.html

:)

Followed this with interest.

Any news or progress?

Len

:)

Long overdue update on the status of my project
 

Fellow Pelicanites,

It is time for a, long overdue, update on the status of my project;

I still can’t believe that my last post was in Nov 2018!
A lot has happened in between…not necessarily as per the original plan.



So where should I begin…

Current status (spoiler alert).
My 930 is running again!
https://www.instagram.com/tv/CXhFimwIyPZ/?utm_medium=share_sheet



I will fill in some of the details with subsequent posts.

The short story:- “ … insanity, is doing the same thing over and over and expecting a different result.”

In my case, my insanity, was biting off more than I could chew and sitting with a project burden that was dragging on for far too long.



The past 2 years have reminded me that life is short.
Driving & enjoying a stock 930, today, beats hands down an over ambitious project that is just dragging on and not materialising...

Regards,
Costa P

Just went through this whole thread Costa, some nice engineering and good info on planned mods etc. Hope you have the car back together and driving again since that video from Cafe 9?

These look brilliant, I'll have to make something like that since I have 3 pairs of crushed oil lines I'd like to fix.

Do you know if the hydraulic shop had those available as a stock item (other than the airline chuck fitting), or were they custom made on a lathe? I'm in Europe so they should be even easier to find in M30x1.5, but no luck whatsover googling for them....


Cheers,
Lukas