WD40 isn't going to do anything to those. You need a torch. If you don't have a torch then soaking the studs in AeroKroil overnight might save a few of them. Christian's tool saved me a pretty major headache.

I will hit it with a torch and some PB, thank you.

Well... good news is that one header is out... bad news is that every single stud gave me a fight. At the end, all but one of the studs came one and it did as a single piece with the nut!

They did not break flush, so that is a good thing... some heat with a torch, more PB, and an extractor and I hope they come out... if not I am going to put Christian's tool to good use.

http://i151.photobucket.com/albums/s...ps59068dad.jpg

http://i151.photobucket.com/albums/s...ps1a28ab83.jpg

http://i151.photobucket.com/albums/s...ps63bc3b25.jpg

And more parts came in... I need to get going and start getting these boxes emptied... need the car to be finished!! I will get going with the engine, finish that and wait...

Got the oil lines to backdate to allow for the headers and exhaust system (that one still not ordered, need to let my credit car recover), new distributor cap, rotor, exhaust studs, clutch helper spring, fuses, valve cover gasket set...

http://i151.photobucket.com/albums/s...psb25ad580.jpg

and also got the tool from Christian (forum member here in Pelican)!! I hope I don't need it, but good to have it handy if I do... need to buy a quality drill bit for it.

http://i151.photobucket.com/albums/s...BA7056B899.jpg

http://i151.photobucket.com/albums/s...ps1b85c7e0.jpg

http://i151.photobucket.com/albums/s...psa4a96e26.jpg

My happy time...

http://i151.photobucket.com/albums/s...7297E95399.jpg

http://i151.photobucket.com/albums/s...7294C2853D.jpg

Will post details later, but the good news is that there are no broken headstuds.

So what do you get when you mix an ignorant with initiative, a cutting wheel, a big f-hammer, and a stubborn exhaust... chaos I tell you, chaos!!

Exhaust/heat exchangers are finally out...

http://i151.photobucket.com/albums/s...pse7217901.jpg

http://i151.photobucket.com/albums/s...psd05c80ff.jpg

http://i151.photobucket.com/albums/s...ps05f12801.jpg

http://i151.photobucket.com/albums/s...ps349e764b.jpg

Oil line out... to be replaced with the backdated new unit...

http://i151.photobucket.com/albums/s...psd409e371.jpg

Removing valve covers to check for broken headbolts

http://i151.photobucket.com/albums/s...ps5413671e.jpg

All of them in there and looking healthy, yeah!!

http://i151.photobucket.com/albums/s...psa706d235.jpg

Removed the CIS as one unit to get the shroud out. I want to clean as much as possible, replace the gaskets and o-rings for the stuff on top... paint the engine shroud, the tins, etc.

http://i151.photobucket.com/albums/s...ps7cb0145a.jpg

http://i151.photobucket.com/albums/s...psbd0db40d.jpg

Removing the engine tins... yes, these can be removed without removing the heads, that was a relief!

http://i151.photobucket.com/albums/s...pse04616d5.jpg

http://i151.photobucket.com/albums/s...psac4de8d0.jpg

http://i151.photobucket.com/albums/s...ps0f08b1af.jpg

http://i151.photobucket.com/albums/s...ps677005e0.jpg

And now installing the valve covers, happy that there were no broken headbolts..

http://i151.photobucket.com/albums/s...729AECB191.jpg

http://i151.photobucket.com/albums/s...7297E95399.jpg

Also removed the oil cooler in the engine to replace seals (turns out those were new...) Now I can get behind the cooler and follow the bulletin to seal the recommended area.

http://i151.photobucket.com/albums/s...72915AC1F4.jpg

http://i151.photobucket.com/albums/s...psa96cbe1c.jpg

6 down 6 to go...

http://i151.photobucket.com/albums/s...ps33b29ceb.jpg

http://i151.photobucket.com/albums/s...ps387260f8.jpg

And on other body-work related news...

http://i151.photobucket.com/albums/s...psa88c5c41.jpg

http://i151.photobucket.com/albums/s...ps4cf0fe34.jpg

http://i151.photobucket.com/albums/s...ps2eccfbab.jpg

http://i151.photobucket.com/albums/s...ps00001643.jpg

http://i151.photobucket.com/albums/s...ps051dace6.jpg

http://i151.photobucket.com/albums/s...ps5d1a2c95.jpg

http://i151.photobucket.com/albums/s...psaeef8242.jpg

A few more... work on the passenger door. Replacing rusted bits. Replacement panels were ordered from our host (those were Stoddard panels):

http://i151.photobucket.com/albums/s...ps9b514a1c.jpg

Also finishing the tank modification... getting rid of the original fill tube.

http://i151.photobucket.com/albums/s...187EB6F544.jpg

http://i151.photobucket.com/albums/s...187CC373B6.jpg

Got the engine tins yesterday... will start putting everything back in the engine tonight and over the weekend.

http://i151.photobucket.com/albums/s...psa9f1bc85.jpg

Did some work on the engine today... done replacing all 12 exhaust studs... and started working on cleaning and preparing the parts to put it back together again...

Shroud just resting on the engine after it was dry...

http://i151.photobucket.com/albums/s...ps1b2d63e0.jpg

http://i151.photobucket.com/albums/s...psa8ff8d03.jpg

I need to decide if I want to keep the fan blades and housing the same color...

http://i151.photobucket.com/albums/s...ps0759c72d.jpg

I cleaned the oil cooler and put a coat of hi-temp aluminum paint just to make it look pretty again... only on the sides, not on the fins...

http://i151.photobucket.com/albums/s...ps579d7ac8.jpg

A few more:

http://i151.photobucket.com/albums/s...psbfd3d84a.jpg

http://i151.photobucket.com/albums/s...ps25263558.jpg

http://i151.photobucket.com/albums/s...pse097159c.jpg

Took the day off to work on finishing the engine... changing seals, replacing bottom oil drain cover (old one looked rusty).

All in all the drain/screen looked great...cleaned all of it and used two new gasket. Back it went.

http://i151.photobucket.com/albums/s...psc68c34fa.jpg

http://i151.photobucket.com/albums/s...pse454b0c8.jpg

http://i151.photobucket.com/albums/s...pscc19d062.jpg

http://i151.photobucket.com/albums/s...psdc9eaf9a.jpg

http://i151.photobucket.com/albums/s...ps5438f485.jpg

http://i151.photobucket.com/albums/s...ps8b358ba4.jpg

http://i151.photobucket.com/albums/s...ps0265fb97.jpg

http://i151.photobucket.com/albums/s...psca53a209.jpg

Engine tins installed... I used the old center units, those were just in need of some paint (but you can see the damage from the surface rust). And new ones for the ones on the ends.

http://i151.photobucket.com/albums/s...ps3f4ea38f.jpg

http://i151.photobucket.com/albums/s...pscf0b112b.jpg

Preventive fill of the area behind the engine oil cooler as per the bulletin...

http://i151.photobucket.com/albums/s...ps9abc8883.jpg

Oil seals in place. It was suggested to put some Loctite 574 on them to make sure there were no leaks...

http://i151.photobucket.com/albums/s...ps77330035.jpg

Installing backdated oil line...

http://i151.photobucket.com/albums/s...ps8ef669b0.jpg

http://i151.photobucket.com/albums/s...ps0ab71e8f.jpg

http://i151.photobucket.com/albums/s...ps510983d6.jpg

Attacking the triangle of oil leaks... I am pretty sure this was already done by the shop the previous owner used...but just wanted peace of mind.

http://i151.photobucket.com/albums/s...psaac36d06.jpg

http://i151.photobucket.com/albums/s...psefb41a61.jpg

New sensor

http://i151.photobucket.com/albums/s...ps8f1635de.jpg

http://i151.photobucket.com/albums/s...pse85aff64.jpg

http://i151.photobucket.com/albums/s...ps37510899.jpg

Now to wire back the alternator, run the wires, and install the fan shroud back so I can install the CIS...

http://i151.photobucket.com/albums/s...psf07fc482.jpg

Always good to have photos for reference...

http://i151.photobucket.com/albums/s...ps51ac5cf6.jpg

Out of order photo... but I took some JB Weld to repair a few areas in the shroud. Painted those before install...

http://i151.photobucket.com/albums/s...ps289a2f78.jpg

Proper sparkplug wires installed...

http://i151.photobucket.com/albums/s...psd0937a5c.jpg

Old go to the trash can...

http://i151.photobucket.com/albums/s...ps5ce3ffcf.jpg

This is the stuff you don't want to find as you are installing everything back :grr:

http://i151.photobucket.com/albums/s...ps8833c15b.jpg

This came with the car... both sides in fiber glass. I had the stock right unit in metal, so I used that. For the left side, this one does not fit well... I will search for a better one... For now I will just leave it out...

http://i151.photobucket.com/albums/s...psd34f0d14.jpg

http://i151.photobucket.com/albums/s...psa93003fb.jpg

Removing the pipe since there is no heat or a/c on this car...

http://i151.photobucket.com/albums/s...ps3e7e0bf9.jpg

http://i151.photobucket.com/albums/s...ps8092c8ce.jpg

Fixing some of the metal with some left over aluminum material that I had...

http://i151.photobucket.com/albums/s...ps585fa355.jpg

JB Weld also comes handy for the small repairs...

http://i151.photobucket.com/albums/s...psc3d2b9a2.jpg

That is all for tonight... more tomorrow:

http://i151.photobucket.com/albums/s...ps1fe5f316.jpg

Wife took me out of the house early...darn it... but I got to see some of the progress with the body work...

Door rust is now fixed...

http://i151.photobucket.com/albums/s...ps868f1be8.jpg

and the rust under the passenger side qtr panel. With this all the rusted areas are now repaired.

http://i151.photobucket.com/albums/s...pse05491da.jpg

Work on tank... you can see a sample spray of the color the car is going to be...

http://i151.photobucket.com/albums/s...psc8d7287f.jpg

http://i151.photobucket.com/albums/s...pse3484140.jpg

Everything cleaned, some grinding to smooth things out, some sealer to make sure there are no leaks... and primer to prevent rust. Plan is to paint the tank a gloss dark gray.

http://i151.photobucket.com/albums/s...ps2d5d2540.jpg

http://i151.photobucket.com/albums/s...psf4444179.jpg

Same as the others...just took a few more. He was not sure about the color and was waiting for me before shooting a larger part... color looks very different in the photos, in person it is a very dark blue with some gray tint to it... I should see some color towards the end of the month...

http://i151.photobucket.com/albums/s...ps7c9ab82d.jpg

http://i151.photobucket.com/albums/s...psa68136bf.jpg

Finally finished the engine tins... well almost, still need to fix some rusted lip on one side... I ended up making the left cover myself with some aluminum that I had. Also made some replacement pieces for the sides, and for the front (where I removed the pipe) I fixed the plate in place with 3 bolts.

http://i151.photobucket.com/albums/s...E12DE1F6F2.jpg

http://i151.photobucket.com/albums/s...E12B092E99.jpg

http://i151.photobucket.com/albums/s...E128239E38.jpg

http://i151.photobucket.com/albums/s...E124269B10.jpg

http://i151.photobucket.com/albums/s...E125CF646B.jpg

http://i151.photobucket.com/albums/s...E122DD5E40.jpg

Tonight I will install the oil return tubes and start working on the CIS. I want to replace the injector sleeves, o-rings, install the new injectors, clean everything on the CIS and install back on the engine. This will take a few afternoons to get done. Plan is to have the engine finished by Sunday... that is my plan at least, let's see how much I get done from tonight until Sunday...

Oil return tubes installed using the suggestion shared here in Pelican. Using a hose clamp. There was not other way...Thank you Pelican Forums!!!

http://i151.photobucket.com/albums/s...psf4c03b28.jpg

http://i151.photobucket.com/albums/s...ps67e02ee7.jpg

Replaced all the boots for the fuel injectors, new o-rings... new injectors with o-rings installed as well.

http://i151.photobucket.com/albums/s...ps493c85ec.jpg

http://i151.photobucket.com/albums/s...ps4e9f33f5.jpg

Installed everything back... only need to look at a few photos to figure out where some of the conectors go and I will be done with the engine. Only thing I need to do now is order the headers and exhaust. Can't wait to see the headers and muffler installed!! ...and the tranny... and everything back in the car...


Before:

http://i151.photobucket.com/albums/s...ps32117451.jpg

After:

http://i151.photobucket.com/albums/s...ps1f3a296b.jpg

http://i151.photobucket.com/albums/s...pseff3687b.jpg

http://i151.photobucket.com/albums/s...psa2e5fc54.jpg

http://i151.photobucket.com/albums/s...ps848e2a2f.jpg

Not much progress lately... should speed up in the next few days.

http://i151.photobucket.com/albums/s...ps4906e29e.jpg

http://i151.photobucket.com/albums/s...ps7cd59131.jpg

http://i151.photobucket.com/albums/s...ps1367368a.jpg

And a larger sample of the color... I like it... turns out it is not as blue as I thought... more like a gray with a touch of blue tint...

http://i151.photobucket.com/albums/s...ps1ec159b4.jpg

While I wait for progress from the shop, I am playing with the idea of some lines... but feel it might change completely the character of the car... I will get them done in vinyl... that way I can remove them if I don't like them or get tired of them... so far, the ones I like the most, are the orange lines...

http://i151.photobucket.com/albums/s...psea87b9f9.jpg

http://i151.photobucket.com/albums/s...pse1630265.jpg

http://i151.photobucket.com/albums/s...ps835bad3d.jpg

http://i151.photobucket.com/albums/s...psfb1dfe20.jpg

Not much progress on this project as Alejandro is working on finishing the details pending on the RSR project...

Figured I would at least post one photo... passenger door repaired.

http://i151.photobucket.com/albums/s...pse764f856.jpg

This color combo looks pretty nice to me.
Enjoyed the pics.
Good luck with the project and keep up the great work.

Plan is to change brakes for Boxster units.

I need to buy the adapter kit, rotors, calipers, pads.

Listing what I need to keep it documented here:

Adapters kit - Pending

Front:

http://i151.photobucket.com/albums/s...ps7fb43a92.jpg

Back:

http://i151.photobucket.com/albums/s...psca8a6f64.jpg

Calipers:
Front left: 986-351-421-03 - GOT IT!!
Front right: 986-351-422-03 - GOT IT!!
Rear left: 986-352-423-01 - GOT IT!!
Rear right: 986-352-424-01 - GOT IT!!

The part numbers for the brake rotors required - Pending :
Front Carrera: 911-351-041-22
Rear 911SC: 901-352-041-14

The part numbers for the brake pads required - Pending :
Front: 986-351-939-15
Rear: 986-352-939-10

Some progress...

Gas tank finished:

http://i151.photobucket.com/albums/s...ps6dec8d01.jpg
http://i151.photobucket.com/albums/s...ps0b75e927.jpg


Rear engine lid finished... pending two more engine lids. Color looks like a dark gray went in fact it is more like a dark lead blue, same color as the photos in prior posts... must have been something with the light and the phone, I will take better photos later. But this is the same engine lid as above...

http://i151.photobucket.com/albums/s...psc70afc81.jpg
http://i151.photobucket.com/albums/s...ps69d16781.jpg

Door handles also painted. I need to pick the up to install the internals and have them ready...

http://i151.photobucket.com/albums/s...ps9a53b66d.jpg

Filler hole finished on the inside of the hood

http://i151.photobucket.com/albums/s...psd9403650.jpg

He is working now on cleaning and preping the shell to paint the trunk, interior, wheel wells, etc.

http://i151.photobucket.com/albums/s...ps6987457d.jpg
http://i151.photobucket.com/albums/s...ps41bd0d04.jpg
http://i151.photobucket.com/albums/s...ps443f4d49.jpg
http://i151.photobucket.com/albums/s...psb77c9b61.jpg

A few more from today:

http://i151.photobucket.com/albums/s...ps54160943.jpg

http://i151.photobucket.com/albums/s...psc152bef7.jpg

http://i151.photobucket.com/albums/s...ps83979d38.jpg

http://i151.photobucket.com/albums/s...ps2ce2817e.jpg

http://i151.photobucket.com/albums/s...psac9f7e28.jpg

http://i151.photobucket.com/albums/s...ps1b8bbb94.jpg

http://i151.photobucket.com/albums/s...ps91c77348.jpg

Did you make any progress in the last 5 month?

Wow nice find. Looks clean!!!

:( Not much... It is coming along... slowly because the guy is working only on Saturdays on the car... and not all Saturdays at that...


I need to stop by and take some recent photos. I will do so next Saturday. Stay tune.

But I did installed the Heuer clock face tonight... :)

Before:

http://i151.photobucket.com/albums/s...ps7ecc8bac.jpg

After:

http://i151.photobucket.com/albums/s...ps8fc77730.jpg

http://i151.photobucket.com/albums/s...psa44496b8.jpg

Well... stopped by last night to look at the car. Not much progress but was promised that there will be a lot of work done over the week. So going again on Saturday to check on it... I was told that it will be painted and ready for me to take it back home before the end of the year...

Photos of the car as of last night... it was full of dust. Next Saturday I will clean it up to take better photos of the color. I want to also take a piece of the leather to see if I go with black or caramel leather interior...

http://i151.photobucket.com/albums/s...521fab28-1.jpg

http://i151.photobucket.com/albums/s...2e8e0fcf-1.jpg

http://i151.photobucket.com/albums/s...d96fdfd2-1.jpg

http://i151.photobucket.com/albums/s...0eee5ea5-1.jpg

http://i151.photobucket.com/albums/s...c18b9f36-1.jpg

http://i151.photobucket.com/albums/s...9bee197a-1.jpg

Fenders will be removed, cleaned, and then painted inside and out... There were put on the car just so that I could take photos...

http://i151.photobucket.com/albums/s...72a00630-1.jpg

Nice work Wachuko!
I'm liking the stripe ideas... I'm especially down with the black center stripe with orange tracers idea. That would look killer!
Wishing I had done the center gas fill on mine. Very nice touch. Mine fills under the hood so I gotta deal with those, less than adequate, hood shocks. Grrr...

Thanks for the favorable mention in you first post... Glad I could be of some sort of inspiration. ;)

Thank you for the kind words. Mine is not being done to the level of attetion to detail and quality of work (body work is, but not the paint...) as yours. I wish it was. But I do not have the funds to get an amazing paint job. At least I know that the body is in good shape, all body work was done correctly, and Alejandro took it down to metal before spraying. Alejandro would be the first one to admit that painting is not his strong suit, but at least it will look very decent. When funds are not an issue I will get it painted again.

On the progress, stopped by today... time was spent fixing a rusted out section in the passenger front fender...

Before:

http://i151.photobucket.com/albums/s...pscfe06345.jpg

After:

http://i151.photobucket.com/albums/s...b0bddb86-1.jpg

Took a few photos of the door handles...

http://i151.photobucket.com/albums/s...psfb8cddd3.jpg

http://i151.photobucket.com/albums/s...psf33b1fc6.jpg

And could not resist to install the clock and the steering wheel just to take a photo...

http://i151.photobucket.com/albums/s...ps223ac5a4.jpg

http://i151.photobucket.com/albums/s...psc329b899.jpg

I will report back next Saturday...

In Rennlist someone asked me the direction with this car... found it cool to recap on where I am going with it...

Sure... I am doing this:

http://forums.pelicanparts.com/uploa...1311088142.jpg

In this color:

http://i151.photobucket.com/albums/s...d3fa67b1b3.jpg

With center-through-the-hood fuel filler:

http://i151.photobucket.com/albums/s...ps051dace6.jpg

Two tone interior in Cinnamon Brown (BMW leather color) and black... Cinnamon dash with black deviating stitching, black knee pad, Cinnamon top of door, with black RS panels, black RS carpet... you get the idea...

http://www.bimmerfest.com/forums/att...9&d=1301346948

Dash face is painted outside color and will have the older (1970's) aluminum dash trim... no heat, no radio...

http://i151.photobucket.com/albums/s...psc329b899.jpg

http://i151.photobucket.com/albums/s...ps6cc36405.png

These wheels (Rota Fuchs styled 17" wheels 17" x 7.5 Front and 17" x 9 back ) with 225/45-17 tires for the front and 255/40-17 for the rear wheels

http://forums.rennlist.com/upload/parts5.jpg

Old Porsche 911 styled sport seats... exactly like these:

http://i151.photobucket.com/albums/s...psd0170b2b.jpg

Still not decided on the rear view mirrors... might go with the chrome older style found on earlier cars...

and this exhaust system:

http://i151.photobucket.com/albums/s...1349807419.jpg

humm... not sure if I left something out... most likely I did...

Received the aluminum dash trim and insert... the insert has to be cut to size, both in lenght and width...

Photo of the insert cut to size and ready to be glued in place:

http://i151.photobucket.com/albums/s...psbc72a62f.jpg

Some 3M spray adhesive, a piece of 1x3 to press against it to make it stick evenly...

http://i151.photobucket.com/albums/s...ps157107d5.jpg

Exacto knife to cut the borders and holes (did not cut the light switch hole, will do that one later...)

http://i151.photobucket.com/albums/s...ps3cb5f4c9.jpg

Rinse and repeat for the other pieces...

http://i151.photobucket.com/albums/s...ps9a737ee2.jpg

Looks like this now though :D

http://forums.pelicanparts.com/uploa...1386262860.jpg

HAHAHAHAHAHAHAHA You show off!!! :D Car is looking great man!!