Millie goes under the knife!

Scooter · 03-16-2007, 08:33 PM

Geeze, I am just so tired right now, I can hardly write. I have been working side by side with a local outstanding wrench that many of you early car owners of a certain Gruppe will know, by the name of Bernie. Millie went under the knife Wednesday for a complete overhaul, including a complete and refreshed SC suspension and a high compression 3.0 liter with Webbers. Now that I have just finished the third solid day of work, I still have another four days left.

As of tonight, we have removed the entire suspension, pulled the engine, power washed the engine compartment, and reinserted an entirely new suspension including:

* A arms
* aluminum cross member
* Koni struts with 3.5 spacing
* Inserts
* 22 mm front torsion bars
* SC calipers and rotors
* stainless brake lines
* turbo tie rods
* adjustable spring plates with new bushings
* 29 mm rear torsion bars
* SC aluminum trailing arms

We stll have to do the following:

* paint the engine compartment
* install the 22 mm adjustable sway bars front and back
* install new 205/50/15 Goodrich T/A KDW NTs
* wire the engine for MSD
* break open and refresh the '72 915 transmission
* install transmission, possibly with LSD (?)
* install 3.0 - 9.8:1 compression and 964 S cam, new SSI heat exchangers and sport muffler.
* install new 21 mm master cylinder
* install new axles

I know I am forgetting a lot, but you get the idea. Why we were in there many unplanned things came up. Oil lines have to be fabricated, the transmission was leaking at the main seal, master cylinder was leaking, and bad axles, among other things.

I told you that the long trip from Ohio to Seattle through Texas and Southern California was just the beginning for Millie and me, and now I feel like I know this car better than any car I have ever owned. A big thanks to Bernie for showing me the ropes!

Here are some pics:

And so it begins:

Engine out:

Will keep you informed as things progress.

Scooter · 11:23 AM

Bad CV Joints:

Goodbye soundpad:

Front suspension:

Engine compartment after power wash:

SP2 · 03-16-2007, 08:52 PM

Wow, Awesome Scott. Damn, you did more in three days what has taken me a year on my SC. Are those Koni struts new or did you repaint them.

What is the significance of "3.5"? Is that for the brake caliper? Do you know what my 69 alum caliper would be? I was thinking of putting a Bilstein strut on.

Did you do this at your house or Bernie's garage? I have heard of him. You must be on some vacation to do all this. Hearty congratulations! Dude, you gotta post more photos...

Scooter · 03-16-2007, 09:11 PM

They are repainted struts. I caught your post on PNW, the struts you want are 3.5" spacing, so you can install your "S" calipers; M calipers have 3" spacing. Randy's struts will not work for you the way you want. The work is being done at Bernie's garage.

cubby911T · cubby911T's Garage

Holy Crap! Impressive Scott!! Millie is going to be a total Bad Ass!!

azasadny · azasadny's Garage

Looks great!!

speedracer · 03-17-2007, 08:18 AM

Looks great Scott! I can see that you have not given in to the "while your in there" mentality....

Gunter · Gunter's Garage

That's exiting.
It'll be a work of art, poetry in motion.
The highlight will be when you turn the key for the first time.
I just installed the 3.2ss I built with the JW-refreshed 915 LSD.
Your heart beats a little faster when you crank a fresh engine for the first time. I pull the pump relay and crank without ignition to build up oil pressure. Replace the pump relay, Ignition ON, Start.
A huff and puff and she somes to life. Check oil pressure immediately. Smoke at first, then clearing, adjust the timing and mixture a little, revving more as it gets warmer, look underneath for leaks.
After 10 minutes, no more smoke, keep revving hard up and down, the rings have seated nicely.
Runs good, sounds good, no leaks. What a relieve!

Scooter · 03-17-2007, 09:53 AM

Yes, looking forward to the first turn of the key and listening to the purr of the motor, then there's the suspension!

Doug&Julie · 03-17-2007, 01:57 PM

Bra-VO!

Is it weird that I still collect photos of "my" car even though it's no longer my car?

Love what you're doing with her, and still so glad to see you enjoying her.

Scooter · 03-17-2007, 07:39 PM

Doug and Matt are previous owners of Millie (a.k.a. Foxy Brown), so they share in my pride of this little car. She will be just a wee-bit closer to her full potential after these upgrades. Thanks guys.

SP2 · 03-19-2007, 12:13 AM

Scott, how did you decide on the torsion bars? Steve Weiner rec 21/26 for my early car because it is light. What do you anticipate with 22/29?

Scooter · 03-19-2007, 06:44 PM

Steve is extremely knowledgeable, but I just wanted to go a different direction. I am trying to set my car up mostly for a track feel, even when I drive on the street. My online research and real life experience led me to 22/29. My setup is definitely not for everyone.

SP2 · 03-19-2007, 06:50 PM

Can you explain in detail how you will paint the engine compartment? I am installing my SC engine (in my SC) this weekend and I might try this if there is time....

Or better yet, can you post some photos?

This is a cool project with not enough photos!

island911 · 03-19-2007, 07:00 PM

Quote:

Originally posted by SP2
Scott, how did you decide on the torsion bars? Steve Weiner rec 21/26 for my early car because it is light. What do you anticipate with 22/29?

I'm going to start calling him "Skip" . .. or maybe "Skipper"

note: I tried talking Skipper (then Scooter) out of it with detailed engineering rational. It didn't work. May have been the beer .. . may have been that no one wants to hear about PDE's and over/under/critically damped spring/weight systems. ...but still, I'm going with "beer" as the reason he didn't listen.

Scooter · 03-19-2007, 07:15 PM

UPDATE: Got the engine compartment painted today, engine is just about put together, and the transmission is open and in pieces.

Engine: Oil lines came in today. Fan and housing is bead blasted and installed. Decided on using updated alternator and installed.

Transmission: Good news! The transmission was very clean and had no metal shavings. Checked the gearing and found that I don't have a stock 7:31. The combination of the small wheels, the 3.0 and the existing gears is going to be ideal for track application. This is a huge plus. I am also installing LSD while I am in there.

Tomorrow is a rest day, but we will be hitting it hard Wed, Thurs, and Fri.

One of the three new oil lines:

Painted engine compartment (looks better in person):

Transmission in parts:

Factory LSD unit:

Engine almost complete:

Whtnkls911 · 03-19-2007, 07:16 PM

Scott,

No wonder your user name is scooter, Millie is going to seriously scoot after this rebuild. Great work, what kind of lift is that?

Scooter · 07:26 PM

Wtnkls911: It's funny, everybody is asking about the lift. It is a Finkbeiner, which are no longer made. I belive they went bankrupt. It is a great lift, because it is very large, but is also mobile, so it can be moved around the shop if necessary.

SP2: I used brush on Rustoleum paint from Home Depot. Bernie said this is the best he has found for this application. It takes about 1-2 days to dry properly, depending on weather.

Island: I listened, but I just can't understand a word you engineers say.

SP2 · 03-19-2007, 10:54 PM

Thanks!

03-20-2007, 03:51 AM

Go Scott go