The Beginning of another project - 911 SC NB RS

[Shuie]

Originally Posted by wachuko

Broken exhaust bolts/studs. Exhaust Stud Repair Tool ordered from Christian... looks like I will make good use of it...

Lots of WD-40 and hoping these come out...

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.

[wachuko]

Originally Posted by Shuie

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.

[wachuko]

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.

[wachuko]

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...



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.

[wachuko]

My happy time...





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

[wachuko]

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...









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

[wachuko]

Removing valve covers to check for broken headbolts



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



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.





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









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

[wachuko]

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.

[wachuko]

6 down 6 to go...

[wachuko]

And on other body-work related news...

[wachuko]

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



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

[wachuko]

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

[wachuko]

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...





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



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...

[wachuko]

A few more:

[wachuko]

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.

[wachuko]

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.





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



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



Installing backdated oil line...







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.

[wachuko]

New sensor







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

[wachuko]

Always good to have photos for reference...



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



Proper sparkplug wires installed...



Old go to the trash can...



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



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...





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

[wachuko]

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



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



That is all for tonight... more tomorrow:

[wachuko]

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...



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



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





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.





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...