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.

For me (so far, & I hope forever) it was putting an early 'road racer' style transmission in my '73 (attached to a 3.2L motor).

I thought the clutch cable replacement would be the hardest project I ever attempted, but it was easy compared to some of the other things I've done on the car.

Replacing the heater/defroster levers on the dash and attaching and running new cables under the dash into the trunk.

Milt,

The glass has etched lines either into or on the glass. But the current is carried by a conductor that is placed on the glass at the factory. After 32 years and many washes, I guess, the conductor had been removed.

There is a repair kit that can be found on the internet. It is meant to repair and not to completely redo the grid lines. I had to tape and repaint or re-brush (the brush looks like a finger nail paint brush) the grid lines.

As for why would you doubt it? I can't say. Perhaps to be a smart a$$?

Mark

Replacing rear banana arm bushings without removing the engine/tranny. I have a later G50 car and I just wanted little monoballs in there.

BZZZZZT thankyouforplaying...

Getting the dust boot on the AL front calipers and getting stuck pistons out calipers.

What?
 

Noah,
How does the "washer and screwdriver" technique work? I searched but didn't find that method. I tried to spread out the spring but nothing I tried worked and I gave up. I'd really like to get the spring installed this winter while the car is stored. Thanks!

I did that once after I reminded myself not to:eek:

Also, trying to reconnect the throttle linkage to the pedal cluster after it fell down into the tunnell with all the other linkages and fuel lines running thru there!

rear wheel bearings can be tough.

front hood shock retaining clip was a pita. after messing with it for an hour i had my brother try and he had it on in 30 seconds!
Front fuel pump is a messy job especially with a full tank of fuel and original rubber fuel line

Here's a funny one!!
After putting on the cam carriers with the engine on the stand, watching a washer fall down the oil return tube into the case!! Then spending 2 hours fishing it out.

So far, the alternator shroud is the worst.... But the hood shocks are in my future :(.

That's a big project but pretty straight forward, does not match the "frustrating factor" of the hood badge :)

1. Convincing the wife to let me buy one.

2. Saving up $17k to buy one.

(Accomplished first, on track for fall of this year with second!)

Cheers,

Paul.

Silly but never the less the most frustrating moment so far in my short DIY career: Replacing number six spark plug. That little bugger drove me crazy.

That pretty well does it for me.

No, I wasn't being a smart ass. If you read what I said carefully, you will see that I inferred that I doubted that there was a viable brush on solution to failed lines on the glass rather than your ability or desire to fix them.

So, I asked if there was such a product expressing my doubt that there was.

As I need to get away from this addiction(Pelican forums), this will help. Thanks.

cam timing
rear wheel bearings

Engine rebuild.....compared to many other types of auto and aircraft engines I have rebuilt, the flat six is definitely the fussiest.

Headliner is not too difficult, just time consuming.

Re: What?
 

Art: I replaced my pedal spring last night. After 1 hour of cursing, I went inside and searched. 10 minutes later it was on. Here's the thread--put a screwdriver in the top hoop and bend it open while holding it in one hand:

http://forums.pelicanparts.com/showthread.php?s=&threadid=314311&highlight=clutch +pedal+spring

Replacing the cabriolet top on mine. It almost drove me nuts:eek:. It took me several days to do it correctly. I now know why the places charge so much for an entire Cab Top replacement(the front fabric and rear window sections) and I decided that I would never do it again. MAJOR PITA!!!!