Hardest or most frustrating 911 project?
 

OK, I'll start.

Getting the Alternator fan back on over the woodruff key without it popping out the backside. I STILL DON'T HAVE IT BACK ON. Gave up last night after about an hour and hit the martini's! I'll be back out trying this AM.

If we exclude big projects like body work 3 small projects comes to mind.
* Hood badge
* Hood shocks
* cam timing (keeping timing while tightening cam nut)

targa rear glass install
replacing master and slave clutch cilinders on a G50
aligning door gaps

Not to forget fixing the problems and "fixes" introduced by previous owners

Trying to replace the large spring on the clutch pedal on the pedal cluster. I notice that the old one had snapped in half when I was replacing my broken clutch cable and I could not get it replaced no matter what I did. I have to remove the entire pedal cluster to replace that spring!!

Glad to hear I'm not the only one who had trouble with the hood badge. I could not get the new badge to seat in the new gasket so I had to re-use the old gasket.

replacing fuel lines from the tank to the engine cmpt.

Absolutley without a doubt? Repainting the nineteen grid lines for the rear defrost on the rear targa glass.

If anyone ever needs to do it, I can tell you what not to do! For one, don't even try to adjust the wiring tabs, they will pop off. Ask me how I know....

http://forums.pelicanparts.com/uploa...1167578733.jpg

- Installing new headliner
- Replacing Targ rear window

Anything involving the CVs
Through-tunnel fuel line replacement
The first 6mo of valve adjustments
Rear torsion bar installation (and DIY alignment and ride height settings)

R&R of the Heat Exchangers on a Porsche from the Midwest or North East.

Hahaha. I'm glad I'm not the only one . . .

I'll add one:

Sewing the zipper on a Cab top. aka: The bigger the needle the more it hurts.

Ian

most frustrating..........


running down a no start/ no spark issue.

Went to MSD and now rocks likes a champ!

Wow, no one has said rear spring plate bushing replacement/torsion bar replacement/ride height adjustment.... Kinda like 3 frustating projects in one :)

Without a doubt this was the worst project for me. Never again. After using a propane torch to burn off remnants of the old bushings and smelling those vapors, I'm done with this job.

Forgetting to transfer the starter ring from the old pressure plate to the new one when doing a clutch job. Nothing worse than hearing that whirling noise at startup time and thinking WTF!

For me..................Targa Top recover/rebuild, along with fitting the targa top to windshield frame seal.

The good news is the info I gleaned from this board made it all possible.

Next project.........front suspension refresh??????????????

I think new headliner has always got the most votes. I just reglued the leading edge under the sunroof. Ended up getting glue in my hair.
BTW I switched to the NAPA brand adhesive. I hate to say it, but it flashes and tacks up a lot better than the 3m stuff.

Couple other good ones on the list. Hood Badge PIA. Then that stupid clevis pin on the bottom of the drivers side front hood shock.
Kind of makes you chuckle at all the profanity events we've had playing with our toys. My grown kids remind me every time I cut them off from cusing. Then I remind them. I'm the Dad. Do as I say, not as I do. LOL.

rust.

And why would someone "repaint" the defroster lines? Is there some kind of repair applied by a brush? I doubt it, but I had to ask.....

How about anything "tunnel" related, like running two new fuel lines. Replacing the tunnel brake line was tough as well.

Replacing the headliner is definetely one of the worst jobs.