Read Wayne's book, 4 hours to install a pop off valve?!?!?!

[Starless]

OK, my 80SC is completely stock. My niece (bless her heart) bought me Wayne's book for X-mas. The first thing I want to do is install a pop off valve, is 4 hours really how long it takes? I'll be using a saw not chewing through the thing! How long did it take you?

[Doug Zielke]

It didn't take me 4 hours, but then I'm sure Wayne is writing for the unknown skills of the masses.
Just take your time. Haste makes waste, and a new airbox is expen$ive.

[DavidI]

It took me about 30-45 minutes. Very easy to do. The hard part is waiting for the epoxy to cure/ dry so you can drive the car!

[Starless]

From reading the project I figured about an hour more or less. I just want to know before I start so I can plan on how much of my weekend will be tied up. Nothing worse than telling the wife "It will only take an hour" and three hours later I'm still in the garage swearing up a storm.

[911SCfanatic]

Plan on an hour to get your tools out, review instructions, cut the hole and do some fitting, mix the epoxy and hold the valve in there for a bit, clean up tools. If you want to make it look really nice plan on another half an hour to take a dremel tool and angle the ribs back around the valve. I think Wayne says to have a 90 degree drill...it's a must. I only post this response because I simpathize with the wife thing...give her a time and if you go over, you're screwed.

[juanbenae]

what he meant is it would take him 4 hour to get there and help you actually install it.

[qcwang]

took me about an hour.

Like Bill G. suggests, a 90 deg or like drill is a must. Here in So Cal. I went to Habor Freight and Tools and bought a right angle drill attachment for $12. It worked great!. However the cheapie hole saw wasn't great and ended up borrowing my neigbors. Oh yeah, have a vacuum or shop vac to suck out the small palstic debris that falls into the hole you make.

Have fun!!

[john walker's workshop]

some epoxies take 4 hours to set up before you can start the car. otherwise the vacuum sucks the epoxy in and you end up with a big air leak.

[vash]

i took about 4 hours. i took my time. i used an milwalkee rt angle drill that i borrowed, and a brand new hole saw. what took the most time was rigging up my shop vac with a one inch diameter hose to vacum out all the chunks from inside the airbox. i cleaned everything out. and i let the car sit for 24 hours before i even started it.

cliff

[William Miller]

I'm looking to replace the o-ring in my pop off valve. Nobody sells them except I might find one at a industrial supply house.
Can you look at the paperwork that came with the pop off valve and give me any info for the manufacturer. I would at least like to know what size they intended to put in there.

BTW don't forget the step about putting some epoxy on the ends of the hinge pin. Mine came out which in turn created a real problem!

Please help me find an o-ring!

[singpilot]

Couple of caveats.

Measure twice, cut only once.

Make sure the top flap can swing open without hitting the filter. Installing it with the hinge on the wrong side makes a mess when you have to tear it out and re-do it. Yes, a drop of epoxy on the hinge pin at one end keeps the pin from sliding out.


Measure twice, cut only once.

[Kraftwerk]

It takes a few hours just to call everyone you know looking for a right angle saw. I never located one but managed to fit the drill in there. Not really recomended though because even if the hole is the right size the hole itself is at a slight angle and you hafta file it a bit... but not too much! It is a 30 min. job which should be done very slowly>> so figure on an hour and 45 min. Then don't drive the car until the epoxy dries overnight. Make sure the springed lid opens the correct way. It should open towards the front following the angle of the inside of the air box. Also locate an epoxy which has a decent heat rating. It gets hot back there.

[CarreraS2]

Originally posted by Starless
From reading the project I figured about an hour more or less. I just want to know before I start so I can plan on how much of my weekend will be tied up. Nothing worse than telling the wife "It will only take an hour" and three hours later I'm still in the garage swearing up a storm.

Your wife isn't very well trained in "mechanic's hours"!

When I tell my wife a project will take an hour, she now automatically hears that as three hours.

[Wayne 962]

4 hrs is about right, from when you turn on the light in the garage to when you drive the car the next day...

-Wayne

[5axis]

Originally posted by singpilot
Couple of caveats.

Measure twice, cut only once.


Measure twice, cut only once.

Sometimes heard around my shop rephrased as

I cut it twice and it's still too small!

[Moses]

My (ex) mechanic put in the pop-off valve in my old 3.0. Did it wrong. Valve opened in the wrong direction. Every time the car would backfire a bit, the pop-off valve would get stuck in the open position wedged against the air filter. I would have to remove the air filter almost daily to reset the valve. Finally I drilled out the pop-off valve and put in a new one myself. Not easy getting the old one out.

Ah, my old mechanic. Great guy if you can look past the lying thief, incompetent moron part.

[on-ramp]

Originally posted by Wayne at Pelican Parts
4 hrs is about right, from when you turn on the light in the garage to when you drive the car the next day...

-Wayne

but when you drive the car the next day, 24 hrs have gone by

???? am I missing something, I'm a little slow these days

[Starless]

On-ramp, you're not the only one I was also wondering about that.
I guess I have my answer, as soon as it warms up a bit, so as not to crack the hard plastic air box, I'll get right on it. Any epoxy better than others? What do you recomend?

[vash]

starless, i needlessly agonized over epoxy. i searched hi and low for the highest temp rated epoxy. you know what? i found some really good stuff at home depot. it is working kick a. (except for what i call affectionately as "the mother of all backfires"). in my opinion, neatness, cleanliness, and following the directions are more important than epoxy type. use a new hole saw, also from home depot that way you can get the best hole. i bet money that my pop off valve will hold vacum without epoxy. well i may be exaggerating, but the valve sqeezed in there perfectly.

cliff

[William Miller]

Juan, see my post above.
Did any papers come with the new pop off valve?