Took out the rest of the parts that need to be powder coated.

Cleaning these two was a pita!

http://i151.photobucket.com/albums/s...ps5span9gf.jpg

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

http://i151.photobucket.com/albums/s...psev1bwerc.jpg

http://i151.photobucket.com/albums/s...ps7un26ylc.jpg

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

http://i151.photobucket.com/albums/s...ps8iyliejn.jpg

http://i151.photobucket.com/albums/s...psuduv6qg0.jpg

And the rest of the parts...

http://i151.photobucket.com/albums/s...psrkm583xe.jpg

http://i151.photobucket.com/albums/s...psqvehev4z.jpg

As it sits in the garage this morning... parts left at the local powder coating place (BNJ Powder Coating).

http://i151.photobucket.com/albums/s...pseemusgw4.jpg

http://i151.photobucket.com/albums/s...psfkmhpeh4.jpg

With the front strut supporting mount removed, I will need to scrape all that rubberized gunk out... I have some paint left, not sure if I will paint that back to the color of the car or just use some semi-gloss black in the area (masking the rest, of course)

http://i151.photobucket.com/albums/s...psurb76zcm.jpg

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

cool, project! looking good.

Thank you!

On other news. Powder coating parts are done! On my way to pick them up. Also a few boxes from Pelican arrived today as well... the rest should be here in a day or four.

:) - I should be able to work on installing some of this back on Monday

http://i151.photobucket.com/albums/s...pss0tmv5af.jpg

Following! This is awesome.

Thank you! Looks like all the parts came in while I was out this weekend. :thumbsup:

Time to work on the car again! Here, a photo after taking everything out of several boxes and placing just the parts in a single box... now to the garage!

http://i151.photobucket.com/albums/s...pspq52tpad.jpg

And unpacked all the powder coated parts...

http://i151.photobucket.com/albums/s...pseej12t9k.jpg

Humm... Ordered what I thought was the correct torsion bar but it looks nothing like the original... calling Pelican.

http://i151.photobucket.com/albums/s...psph2ompie.jpg

http://i151.photobucket.com/albums/s...ps3z0lze7s.jpg

http://i151.photobucket.com/albums/s...psst386bsm.jpg

Strange because the part number in the box and the description all points to the correct part, but no way this can fit where the old one is... Here, it has two labels...

http://i151.photobucket.com/albums/s...psrmwx4yto.jpg

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

Looks like I got 27mm rear torsion bars

http://i151.photobucket.com/albums/s...psn5u1thgj.jpg

Too bad these are not 28mm or I would have kept them for the rear...

This was easy... Elephant Racing Strut Top Camber Plate Bushings

http://i151.photobucket.com/albums/s...psv6nmmxs8.jpg

http://i151.photobucket.com/albums/s...pskbh88sbr.jpg

http://i151.photobucket.com/albums/s...ps1tlgh1d8.jpg

Mounting the ball joints

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

http://i151.photobucket.com/albums/s...ps15pcmlnw.jpg

I will install the other bits later...need to check what the torque value is for that nut...

Also installed the rubber bushing in the a-arms.

http://i151.photobucket.com/albums/s...pssoone43v.jpg

I think that I need to wait for the instructions of the torsion bars to find out the correct angle for the bushings?? I need to look at the book... let me insert the bushings while I get the book...

http://i151.photobucket.com/albums/s...ps0ibghokt.jpg

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

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

Removed all the gunk from the shock tower area... painted it flat black on top and underneath to protect it from rust.

http://i151.photobucket.com/albums/s...ps1bgmbiff.jpg

http://i151.photobucket.com/albums/s...ps2lqizlim.jpg

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

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

http://i151.photobucket.com/albums/s...pscdlv9lxp.jpg

Removed steering rack. Forgot to order the rubber bushing with the bearing inside...will order tonight with a few more things... Removed the tie-rod ends from the rack.

http://i151.photobucket.com/albums/s...psvg1lujgo.jpg

http://i151.photobucket.com/albums/s...ps5oydmtcl.jpg

http://i151.photobucket.com/albums/s...pse4i2dck4.jpg

Installed the mesh and frame at the end of the hood...used the wrong screws but those are just in there until the correct ones arrive.

http://i151.photobucket.com/albums/s...pssdikx30k.jpg

Only held in place with one bolt... will align it better, and install the other three bolts, tonight after work...

http://i151.photobucket.com/albums/s...psglem6zrp.jpg

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

Also forgot to mention that I got the original rubber gasket for the fuel sending unit and it worked like a charm... sometimes the best part is the original part... the gasket that was in the boxes of parts that came with the car would not align correctly :rolleyes: . New nuts and washers are on their way. I have a new plug cover... forgot to get this one to powder coating. I will just install the new one that I have in yellow zinc finish.

http://i151.photobucket.com/albums/s...psb5kgakeg.jpg

Can't do much until the rest of the parts get here...so baby steps. Installing the spacer on the strut mount.

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

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

http://i151.photobucket.com/albums/s...psmbo37lt0.jpg

Rinse and repeat...

These are done...

http://i151.photobucket.com/albums/s...pseshoi5rr.jpg

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

For a minute there I thought the hubs were painted black... It is all accumulated brake dust...

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

More cleaning left to do... I should have used the soda blaster to begin with...

http://i151.photobucket.com/albums/s...psrg3xmubl.jpg

I waste so much time installing parts just to look at them...

http://i151.photobucket.com/albums/s...psxg2a3xln.jpg

Preparing the hub for the bearings...

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

I am doing my own yellow zinc with the bolts I buy locally... Sumerge the bolt into the prep liquid, wait 20 seconds, rinse in clean water, dry with heat gun (to avoid the wait), and voila!!

http://i151.photobucket.com/albums/s...psp16auu2e.jpg

http://i151.photobucket.com/albums/s...ps5gbxdwoa.jpg

I did not know that the hub were specific to sides... These were marked as such...

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

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

http://i151.photobucket.com/albums/s...pszjok8pub.jpg

Done! (well...still need to install de grease cover)

http://i151.photobucket.com/albums/s...ps5s4t8pfm.jpg

Just to be clear... I am only using yellow chromate to get the finish on new zinc plated bolts that I buy locally... Yellow zinc plating is a two part process... first you zinc plate the bolts and then you run them by a solution that gives it the color.

When I ordered the zinc plating kit from Eastwood (btw, this is still in the box and have not used it...) , I also ordered some yellow chromate from Caswell... ...mixed some distilled water and 2 oz of this product....

http://i151.photobucket.com/albums/s...psc8b4506c.jpg

I felt like I was dealing with plutonium...this came inside two boxes, and then the can was in a sealed bag...

http://i151.photobucket.com/albums/s...ps0aa092df.jpg

http://i151.photobucket.com/albums/s...ps99059f54.jpg

http://i151.photobucket.com/albums/s...ps03ea9c5e.jpg

Let's try a few parts... those new nuts look clean...

http://i151.photobucket.com/albums/s...ps38d089f1.jpg

http://i151.photobucket.com/albums/s...ps47c8875d.jpg

http://i151.photobucket.com/albums/s...ps63e202f3.jpg

Rinse with clean water and dry with a heat gun at low setting...

Does not work on anything but newly zinc plated parts...

Cool find on the chromate solution! How do the parts look next so factory zinc/cad plated stuff? I guess it depends on how long you soak for and the original plating. They look good to me!

Very nice way to treat fasteners from the hardware store and those annoying Porsche parts that don't get the yellowing treatment.

Factory parts were cad plated... So they do not look like that. Cad plated parts have a finish that is not as shiny. Everything that I have done on the other project ('67 912) has been yellow zinc electroplated. This looks identical because it is the same process.

And yes, I agree. It is great to be able to give these bolts a similar finish to match. Too bad it can only be done to stuff that has been zinc plated... can't do it with the stainless steel bolts.

Here, take a look... these are parts that I had done by a local shop for my other project ('67 912)... yellow zinc electroplating... they look the same as the bolts I did at home:

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

Forgot to add the link to this process... found it in Rennlist, so I did not see the need to do a complete walk through on it. This is one great write up of the process. Thank you Dwayne. First time that I ever see the actual tool that is used to remove the grease/dust cover...

1984 FRONT WHEEL BEARINGS AND BRAKES PROCEDURE w/PICS

Was not able to do much last night... only rinse and repeat with the driver side hub/rotor/caliper... both sides now installed. I still need to validate/check on how tight the trust bearing nut needs to be... some black magic to get this right... the trust bearing washer needs to be so that it can move just a little with flat screwdriver... can't even see the darn thing because of the grease, how am I going to validate that I did not over-tighten it!?

Dust/grease shields are just in place for the photos... once I see a few videos and read that thread again, I will check the trust bearing nut again...

http://i151.photobucket.com/albums/s...ps0eajh1yq.jpg

http://i151.photobucket.com/albums/s...pscajcmp6v.jpg

http://i151.photobucket.com/albums/s...psiz8yb4jm.jpg

Correct front torsion bars arrived yesterday... shipping the incorrect ones today.

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

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


and also the wrench I needed for the tie rods... Super B 32 and 36mm Headset Wrench


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

Hi Wachuko,

This thread is very inspiring. I have my SC torn apart and I am currently rebuilding the front end. I took the rack and pinion apart for grease and bearings about a week before you mentioned working on yours. My original torsion bars look similar to the picture you posted. Did you just want stiffer ones or do you think the old ones were too pitted to reinstall? I am asking because I wonder if I would be better off replacing mine. Thanks for your updates.

Paul

Paul,

I was afraid on installing back the stock torsion bar due to the rust it had... did not wanted it to break shortly after installing it... specially after all the work in the rest of the suspension... felt safer to just replace with new ones. Rust kills the torsion bars...

I was not looking for anything different... went with those since it was the least expensive option and the 21mm front and 28mm rear is the most recommended combination here in the forum.

Worked on re-greasing the steering rack, new turbo tie-rods, spacer, boots, etc.

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

The guy in the link I posted earlier, had 26 rollers in his needle bearing... mine had 29... go figure...

http://i151.photobucket.com/albums/s...psv97z0atv.jpg

Bearing grease re-packed...

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

http://i151.photobucket.com/albums/s...psmzowcei4.jpg

Turbo tie-rods

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

Rubber boots installed...

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

http://i151.photobucket.com/albums/s...psmfk550cq.jpg

Done... now to tackle the A-Arms... need to find what the angle is supposed to be for them... indexing is it call??

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

https://youtu.be/85-Enx4bKUE

Both A-Arms done! Going to sleep!

http://i151.photobucket.com/albums/s...ps9z05ugp0.jpg

A-arms are now done! Ball joints torqued to specs (109 ft-lbs). Rotated the ball joint shaft to the correct direction...washer and cotter pin in place... Break for breakfast with the family...will be right back :)

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

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

Hehehehe they are done...I did bend those into the slots

I never complain about calling stuff like this out. In fact, I appreciate you reminding me that. Better safe than sorry. Thank you.:thumbsup:

Back in the house now... took a few more photos. Both are secured.

http://i151.photobucket.com/albums/s...ps7qlik1zp.jpg

http://i151.photobucket.com/albums/s...psonkrkj7b.jpg

More...

http://i151.photobucket.com/albums/s...psnai9kkqx.jpg

I will not let it get rusted back in place...

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

A photo of grease being applied... took a photo before my hands were to the point where I could not grab the camera again...lol...

http://i151.photobucket.com/albums/s...psqsodnt0y.jpg

Foam thingy in place... and to me, that foam is the culprit of these bars getting rust in there... they don't seal anything and just trap moisture and dirt...

http://i151.photobucket.com/albums/s...psip8fksg9.jpg

Now... where did I put the adjusting bolt?

http://i151.photobucket.com/albums/s...ps7cgzpebn.jpg

Rinse and repeat...

http://i151.photobucket.com/albums/s...psyfh3fw0a.jpg

Done...

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

...well, not really... can't find one of the adjusting bolts for the torsion bar, arghhh... cleaning the area to see if the time-people forgot to put it back... oh, and the needle bearing with the rubber bushing that goes on the steering rod, comes in on the 4th <sigh>

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

Photobucket is having issues... anyway... will try to load photos when I can.

I was waiting for the bushing for the steering rod when I remember that I had the 912 rack rebuilt and with a new one... since that will wait until the shell is back, I just removed the rubber bushing with the needle bearing from it. I will install the other new one when it gets here... I used a little bit of black gasket silicone on the base of the plastic cover, just to secure it in place and avoid anything coming up through there... water, whatever that could dirty/rust the inside bolts...

Let me see if this works...

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

With that done I was able to install it all back in the car... Daniel helped me. Pretty cool seeing him wrench. It was funny because, at first, we try to wrestle the suspension by ourselves... boy was that too heavy to manage!! I forgot I had those telescopic/high-lift adjustable jack stands... so out those came, placed under the crossbar while we install the bolts... everything else was pretty easy after that...

http://i151.photobucket.com/albums/s...psu5cxid4v.jpg

http://i151.photobucket.com/albums/s...ps5egqinih.jpg

http://i151.photobucket.com/albums/s...ps0jy8uoxz.jpg

Finished task...

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

Started connecting fuel lines... need to find the fuel pump... is in one of the remaining boxes...only three boxes left!

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

Well... for the life of me I can't find the box with the gauges, steering covers, and Momo mount rubber boot... and I know I have them because I took a photo BEFORE I took them out... and I have the clock... Just like what happened with one of the headlights, it must be hiding inside a box that is inside something else...

http://i151.photobucket.com/albums/s...pshom1twbz.jpg

Sucker for tools... looking to replace the rear bearings while I am there... but no way I was going to pay 369.00 for the tool I saw in one vendor...

There is always the HomeDepot alternative...

http://forums.pelicanparts.com/uploa...1122982665.jpg

http://forums.pelicanparts.com/uploa...1178846048.jpg

But decided to go for this one: Bearing Removal/Insertion Tool

http://i151.photobucket.com/albums/s...ps32paxfip.jpg

Found the box (turned out it was in an old plastic toolbox!! ) with the missing interior bits... gauges, steering covers (these you can't find anywhere!!), momo rubber hub cover (now I need to see if I can return the Momo hub I bought from here (Pelican) )... I am so happy! :)

http://i151.photobucket.com/albums/s...ps1r9zuamj.jpg

Well, bearing removal/install tool came in... also all the other parts that were delayed, came in today!!

http://i151.photobucket.com/albums/s...pseu8wsdvs.jpg

I have everything for now to continue working in the SC and in the 964... yeah! Looking forward to the weekend!!

Baby steps...

Daniel installed the passenger floor board... we went back and forth if installing under the carpet or over it... and I still need to paint the bottom plate holder black...

http://i151.photobucket.com/albums/s...psq0teuzt7.jpg

Installed the rubber retainer with needle bearing... connected steering rack...

http://i151.photobucket.com/albums/s...psl4s8kxgi.jpg

Replaced the screws in the vent frame with the right ones (and in black as well)

http://i151.photobucket.com/albums/s...ps1hb7j6x1.jpg

Installed the nuts on the fuel sender, plug in place, and plug protecting cover installed. Had to treat the nuts since those came in zinc finish...

http://i151.photobucket.com/albums/s...ps6glirih4.jpg

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

Now to install the block-off plates that came in...

And to finish installing the front brake lines, 930 master cylinder, etc... basically, to finish the front brakes install...

Finished the front brakes... lines and all...

http://i151.photobucket.com/albums/s...psjp5dl9uw.jpg

http://i151.photobucket.com/albums/s...psp3ahdnjq.jpg

The kit for the brackets to install the Boxster calipers came with brake lines... rubber inserts for the shock mount bracket... I had to enlarge the bracket hole to allow for the line fitting to go in...

http://i151.photobucket.com/albums/s...ps36psjevp.jpg

With the front brakes done, I went to installing the bracket for the fuel pump... Lucky that I had a new bracket in the pile of parts since the previous owner had powder coated the original in yellow and I forgot to send that in with the rest of the parts that got redone in black...

http://i151.photobucket.com/albums/s...pszgc4iq4x.jpg

http://i151.photobucket.com/albums/s...ps7xeliwdx.jpg

That is it for today... just got back from celebrating a friends 70th birthday and there was wine involved... so I can't see well, lol... Good night!

Very nice work.

Thank you!

Okay... I know the strut inserts are Bilstein... but I like the Koni sticker more... :) And since this car is made up of sooo many different parts from different years, who cares!

http://i151.photobucket.com/albums/s...psigm1jq0j.jpg

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

These wheels are in good shape... but I am installing 17" rotas that are in boxes waiting for me to finish everything before I get tires for them... and the market for 6" and 7" is so low that it is not even worth selling them... I will store them for any future project that might have...

http://i151.photobucket.com/albums/s...pstq1fhndb.jpg

Removed the heater controls...

http://i151.photobucket.com/albums/s...pslspwo2lu.jpg

Covers in place...

http://i151.photobucket.com/albums/s...psc87fe9so.jpg

Removed rear shocks, spring plate, brakes, and bearing...

http://i151.photobucket.com/albums/s...psh7nqiyhk.jpg

http://i151.photobucket.com/albums/s...psgiuj0mas.jpg

http://i151.photobucket.com/albums/s...psrqrnmhi8.jpg

Rear shocks are Bilstein Sports (4298-B46-0169 H0)... so looks like I will have to get Bilstein HD for all corners... since using torsion bars 21F/28R :(

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

http://i151.photobucket.com/albums/s...ps1d2wzlfs.jpg

http://i151.photobucket.com/albums/s...pss8epw3fl.jpg

http://i151.photobucket.com/albums/s...psemp71eoi.jpg

Bearing removal tool worked like a charm!!

http://i151.photobucket.com/albums/s...ps1oqxwsjw.jpg

http://i151.photobucket.com/albums/s...ps5uwppmai.jpg

http://i151.photobucket.com/albums/s...pse3uxr7ao.jpg

This side done, need to work on the other side...

http://i151.photobucket.com/albums/s...psvx4izo8e.jpg

I promised myself that I was not going to do this with this car... this is a driver, so there is really no need for every single bolt to be nice and shiny... guess that I will have to eat my words... making a trip to Seminole Metal Finishing for getting all these nice and shiny... will add the spring plates that I just removed as well... later I can decide if I go with the powder coated or yellow zinc...

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