1984 Cabrio - Long Term Project

[GeorgeK]

As of now, I have been into Porsches for 23 years, 911s for 19. After a 944, the Orange Carrera 3.0, the '83 930, the '73 RS (and a Turbo Cup car), I had a hiatus while living and working in Montreal. After coming home, buying a house, having a kid.... you all know how it goes, the itch came back, and was scratched with the salvage of an '89 C4 (named Shrek, after its horrendous condition when I bought it). The C4 became my daily driver and has been for the last 5 years. Its evolution is documented on rennlist.

With the Shrek being reasonably done and reliable, I turned my interest to another possible project. I wanted a 356, but prices are bordering on insane for my means/my willingness to spend. After realising that, I listed my conditions, my needs:
-Daily driver, about 20 miles a day, some mountain, some town roads,
-250-300 days of sunshine a year,
-Can be a spring/summer car only,
-Simple, reliable,
-maintenance friendly, with no dealer-only tools or compouters needed,
-Euro car, that is registrable with the nazi-like swiss administration.

With that in mind, I turned to cabrios. Hey, if I use it only in summer, only for commute and in sunshine, I might as well enjoy the scenery. Perusing the classifieds on here, I found after a while a good candidate: Euro '84 cab, german origin, in Georgia, near Atlanta. The seller was a gentleman with good patience and knowledge. A PPI was duly performed and uncovered no deal-stopping issues. So a deal was made, money wired, and the car was brought to Savannah for cargo shipping.

Hereafter I would like to narrate and illustrate the journey that followed. It has been a very good investment of my energy and money, for I have a car that brings me smiles and gives me an escape for when day-to-day life gets overbearing.

So first, a few pictures of the car from the seller:

[GeorgeK]

The seller kindly drove the car to Savannah after my having arranged for shipping roll-on roll-off, with Wallenius Willhelmsen, who seem to be the world's largest automobile carrier. Cost was surprisingly affordable, coming in at about 1100$ once port charges and custom documents were done and ready. This amazed me, seeing that shipping a 4 lbs bicycle frame can get to 200$...

As he arrived to the port, the car would not start any more. Oh oh... Ro-ro turned into "strap on a huge pallet and forklift into the ship" deal, with a surcharge that he seller took over. I could then follow the boat's track thanks to satellite location.
While this happened, I had to arrange picking the car up at port in Zeebrugge, Belgium. Since it was no longer registered anywhere (and wouldn't start), I had to transport it. My mechnic stepped up and offered to drive (with) me to the port and bring it home on his covered platform truck. Heated, seats, music, 20mpg at 75 mph, and a driver that is a living encyclopedia on 911 and racing over the last 40 years. Perfect combination. I booked a 4 star hotel in Brugge, and we set off one foggy late november morning. After an uneventful 10 hour drive starting at 4 AM, we arrived in time to go to the port, get import papers, pay the freighter and pick the car up. A try at starting the car proved unsuccessful. Crank, but no fuel odor, nor spark. After that, a short visit of Brugge (the Northern Venice) and a good night at the hotel, and we were set to drive home. Arriving the next evening at the swiss border, the shiite hit the fan. Where are these and those forms? We can not tax it at 9PM, you need to leave the car here until tomorrow morning... The hell we are. After kindly reminding the border official about some rules and laws of personal imports, he let us through with the correct document stating that we must pay import tax on the car within 72 hours. 8.5% sales tax, then other miscellanei, bringing the total to 12% of invoice value.

I left the car with my mechanic on the truck, and while I went back to work the following week, he proceeded to bring it to the local import offices, have the car's VIN and engine number recorded (wrong, this will have some bearing later on), pay some money, and the car was now legally in Switzerland. I could look at it, tinker with it, but not drive it. For that I needed to have it inspected, by the local vehicle nazis. Another saga brewing.

Here it is as we first saw it, then on the truck, waiting to be scrutinized by customs. A quick survey demonstrates some defects to be worked on.

[Smoove1010]

That's a beauty! Long term project? What needs to be done? It looks ready-to-roll and enjoy to me! Good luck,
GK

[hhackma]

Good story! Please keep it coming.

[GeorgeK]

GK, While the car was in *stellar* condition for its age, there were some areas that were worn, some modifications that ddid not meet my aesthetic criteria, and I had some plans for it. I also discovered that the left side door was made of about 30% bondo, following a likely over-opening accident. The sculpting was first class, but the door's edge was clearly in a bad shape.
Here are a few pics while it was waiting to be legally imported, and before we could tackle the no-start condition.

[msterling]

Number one suspect for no-start is the DME relay. It plugs in under the driver's seat, right next to the larger DME box. There should have been a spare in the glovebox (don't drive a 3.2 Carrera without a spare). That's where I keep mine. When it fails, there will be no power to the fuel pump. Other causes of no-start; CHT sensor (cylinder head temp.), fuel pump failure, DME computer failure, flywheel reference sensor. Your mechanic should be able to figure it out pretty quickly without my advice.

This is not to suggest that 3.2 Carreras are unreliable. I have had mine for 11 years and it has started and run perfectly 100% of the time. Maybe yours just hated to leave her previous owner.

[Ferrariguyma]

Subscribed and congrats on the new to you Cab

[GeorgeK]

Msterling,
You'll notice that I use the past tense in my description. The car arrived late november 2012. I was recently cleaning my hard disk and realised I have pictured most of all the work I have done on the car, and I could start a documentary type thread with the mods and remedial work performed. I still dd the car, sometimes partly dismantled, and it is not yet where I want it.

It was not the DME relay.

[cabmandone]

Nice looking car!

[GeorgeK]

[msterling]

Originally Posted by GeorgeK

Msterling,
You'll notice that I use the past tense in my description. The car arrived late november 2012. I was recently cleaning my hard disk and realised I have pictured most of all the work I have done on the car, and I could start a documentary type thread with the mods and remedial work performed. I still dd the car, sometimes partly dismantled, and it is not yet where I want it.

It was not the DME relay.

It looks like I failed to read your mind. You didn't mention the time frame. The last comment was "Here are a few pics while it was waiting to be legally imported, and before we could tackle the no-start condition.". I doubt that anyone realized that the car had been in your hands for 2 years. Anyway, cool car and a nice story.

[Ferrariguyma]

I have a new to me 1985 RoW Carrera Cab I just got the COA and the only options listed were "Equiptment for Germany" and Cruise Control. A/C was added when it was imported and I am having the entire A/C system removed returning the car to "as built". Can I ask for a photo of your center console? It looks like your car does not have A/C and I am curious what switches would be in the center console on a car delivered without A/C

Thanks!

[GeorgeK]

Originally Posted by Ferrariguyma

I have a new to me 1985 RoW Carrera Cab I just got the COA and the only options listed were "Equiptment for Germany" and Cruise Control. A/C was added when it was imported and I am having the entire A/C system removed returning the car to "as built". Can I ask for a photo of your center console? It looks like your car does not have A/C and I am curious what switches would be in the center console on a car delivered without A/C

Thanks!

Wish I could help, but my car also had an AC retrofitted when it arrived in Florida in 1984. The work was substandard, and aftermarket knobs were grafted to the center console. So no pics of it originally.

MSterling, my bad. What seemed obvious to me wasn't from reading. Edit: well, I mentionned we went to pick it up in November...

[GeorgeK]

Getting it homologated/inspected/registered

Having the car legally in Switzerland is one thing. Getting it registered is another.
You see, Switzerland is not part of the european union, has ist own laws and rules, and prides itself on doing things the right way – right I can’t tell, but very swiss for sure. Hang with me:

In 1983, Porsche introduced the 3.2 Carrera to the world. New engine, new brakes, new electronics (Motronic). When they did that, they established a « bordereau type » , which is a technical document describing the car. EVERYTHING was described, from piston diameter to… brake piston diameter, from wheelsize to steering wheel size, from exhaust system to cooling system, from seatbelts to fan belts. Porsche made this document available to all countries that wished to import and sell the car. The Swiss importer officially announced to the authorities that they intended to import and sell the 3.2 Carrera in its 3 body forms. And they provided the central automobile authority with such a „bordereau type“. Very well. Except, there were a few typos in the documents, and it was written for the coupe body. When new, it was not an issue, since the various offices giving registration inspected new cars that were not even sold yet, so they all passed the std inspection with flying colors.

Fast forward 29 years: I went to the registration/inspection center. The lady at the desk looks at the US registration paper and says point blank: this car is not swiss, it must go through single car homologation. That process costs easily 10K ChF.

Well, no. You see dear lady, in 1984 there were 3 types of 911: USA, Japan, and the whole wide rest of the world. As you can clearly see on this VIN: WPO ZZZ,… it describes clearly a non-US, non-Japan car.

« Grmblblbl… Get me a paper from Porsche Switzerland stating that it is indeed so, and we’ll study the whole file and see if we give you an inspection appointment »

OK, no problem. I call Porsche Switzerland, and explain. Answer from the lady at Porsche Switzerland: „We don’t deliver these certificates, Porsche Stuttgart does“

Ok, no Problem, I call Stuttgart „ We don’t do these papers, the Swiss importer will do that“

Ahh, ermm, OK. I call Porsche Switzerland back, the same lady tells me again „Porsche Switzerand does not give these documents“. Me: May I have your name, so that I can tell Stuttgart who it is in Switzerland that knows better than them?“ Her: « wait », puts me on hold. …Music…music… like I only have this to do in my life…Music… « Are you here? Get the car to an authorized dealer, who will inspect the car and give you a letter stating that the car is indeed as it left the factory, and corresponds to the Swiss « bordereau type » ».

Shouldn’t be hard. I call an acquaintance of mine, who runs a Porsche dealership and arrange for the (by then repaired and starting car, with the original exhaust fitted) to be driven there. Get the car back with a written document stating that the car indeed is conform to the Swiss rules. Send that to the main importer. Wait… wait,… wait. After 2 weeks, I get an email asking: Where are the photos? -Which photos? -The ones that should have been shot by the local dealer, displaying the car from sides, back, front, rear. – Ok coming right away. Drive up to the workshop, shoot pics, add a few of the engine with numbers in plain sight, of the gearbox. Send them back the same day. A week passes……. Get an email: „where are the exhaust numbers?“ –Huh, which numbers? „ the ones from the side and back exhaust, part number and homologatin type? Uh oh… No parts visible on the exhaust we fitted here. Ask my mechanic, digs in his ‚80’s papers and gets them, e-mail them to the importer, and a week later, get a document stating that the car is indeed as it should be, meets the Swiss homologation details.

Whew! It’s over!

Except it’s not. To be followed.

[CountD]

Ah, Switzerland...chocolate, coo-coo clocks, and festivals for chocolate and coo-coo clocks...

[78-911SC]

Going to be an interesting project.

[GeorgeK]

Inspection, registration, wheels

By then, I had a car that the importer certified in writing was conforming to its homologatin papers. I still needed to pass it through inspection. I brought the file with all official documents I had and after a 2 week "file study" process (that took me 20 seconds), got an appointment... 4 weeks later. Before that and in the time leading up to the inspection, I had to prepare the car.

Pollution test: no big deal, it sailed through without even opening the engine lid.

No start condition: that was solved first and was traced to the engine position sensors, in front of the engine, by the clutch. Only problem was, the sensors were truly stuck to their bracket. So much that the engine had to be dropped, the bolts holding the bracket torched out, and the remains of the old sensors machined out in a lathe. 2 oil return tubes were changed at the same time, more from "while you're in there"-itis.

Wheels and tires: the 6&7 x 16 wheels were in great condition, with their center painted slate blue, the color of the body, but a front tire was unevenly worn due to a msaligned geometry, so new tires were due. the tires were also over 7 years old, a thing that gets checked at inspection. They were also quite hard. In my plan of action, I had a set of 7&8 x 15 Fuchs, that had been sitting on a shelf since about 10 years, so I pulled these out, finished polishing them and had them clear anodised, to match the finish that was available in the period. I also bought N homologated Pirelli P6000 in 195/65 and 215/60 sizes. The combo is much lighter than the 16" that came off, and better meets my liking.

From the period catalog:




So came the day of the inspection, and it got interesting. First thing they do is check the chassis number. well it was transcribed wrong at the import offices. They wanted right away to kick my mechanic out, thinking he brought *another* car to inspect. It took a while to convince them that a 911 chassis number has 17 digits, and that the digit missing was the one describing the body type as a cabrio, but they reluctantly gave in to that.
Remember how I told you that the swiss importer made a few mistakes in the "bordereau type"? Well this came back to bite me in the rear end. The wheels homologated in said documents were 6&7X15 (the series phone dials), the 6&7 X 16 Fuchs, and 6&7 X15 Fuchs, or 6&8 X 15 Fuchs. But no front 7X15 wheels . Never mind that 99% of 3.2s in Switzerland have 7s in front, mine wouldn't pass, It was useless to argue. "If it says so on the documents, your car must be like that. No exception". It was a matter of swapping the front 7s for 6s, but it failed the inspection right there.
But wait, there's more! I mentionned that the bordereau type was written for a coupe. Well the coupe is a tiny bit taller than the cab... You guessed it, too low, even though it looked like a drunk moose on stilts (raised for the inspection) it was stil about 4cms too low. "See you next time, with better luck, we hope!"
So it was up to the workshop and start working. In the end, my mechanic changed the excentric washers that adjust the main bow height for larger ones allowing them to push the top that bit higher. That did the trick, and by then the top looked like a hunchback, à la '55 Speedster. The front rims were duly swapped for 6s that got a lick of silver paint to look like the rears and that was it.
I got my "Carte Grise", or registration papers, a set of license plates. Nothing else. They kept (there's another word for that) the Georgia license plates, the original registration papers. In fact they kept a good scan of the reg papers, since I had scanned it and printed a color copy.
At lease I could drive the car, and start working on it to bring it to my vision.

[GeorgeK]

Wheels before final polish:



After anodising:



On the car:







Of course, nice 15" wheels were meant to be complimented by a good looking spare as well:

[hhackma]

Good story! Please continue.....

[GeorgeK]

Steering wheel
Now that the car was mine, driveable and legal, I started using it as a DD for that last summer (by that time it was September 2013). The updates will now be shorter, since there was much less drama involved.

The car as deliverd had a standard 3 spoke steering wheel, with the optional extended hub. It is a good option for me, since I have long legs. The wheel had been recovered, but certainly not correctly, There were creases at the spokes, the bottom center stitching line was off center, and the stitching pattern was a rather childish "round and round" instead of the factory "zig-zag".

Luckily I still had a rather large steering wheel stash, out of which I pulled a fat rimmed wheel, that had been stored since new (or so I was explained when I got it). The leather is indeed in excellent condition, but the wheel was stored face down on a shelf, and there are some pressure lines visible. It was still much better than what came off, and had a fat rim, which I prefer. I also did a hub transplant to have the extended hub, and then added yet another hub spacer that a local workshop made for me following a skecth I made, and which I then covered in black leather. Looks a bit weird from the side, but function trumps all.