I really didn't want a project this big....yet...

[DaddyGlenn]

Thanks guys!

[MichiganMat]

Originally Posted by DaddyGlenn

Fabricated the seat mount bracket for the passenger side. My welding skills improved since I did the driver's side.


...

Saw this and was reminded of the time I tried to weld my seat bracket and inadvertently melted the plastic fuel line and return line that runs through the tunnel. Nearly burned the car to the ground. I hope you removed those lines before welding... just fyi, wouldn't want anything to happen to your project. Nice build!

[DaddyGlenn]

Thanks Matt. I did remove the old lines and I have new lines waiting for installation.

[DaddyGlenn]

This weekend, the new fuel lines went in. What a pain! This was one of those tasks that teaches you a lot the first time you do it. If I ever have to do it again, it will be much easier.

Lessons I learned:

• Take a picture of how the lines route around the steering rack and cross member. I didn't and need some help here. (hint, hint)
• A small mirror and a flashlight are very useful when trying to see in the tunnel
• It is a single channel through the tunnel for both lines.
• A pull string in the tunnel can melt just like the fuel lines when you weld in new seat mounts.
• Pull both fuel lines through at the same time.
• For my vintage SC, the return line is on the driver's side, supply on the passenger side. (a note I failed to make when I removed the lines over a year ago.)
• Tape over the ends of the fuel lines before pulling them through to keep dust and dirt out of them.
• Have a second pair of hand available and willing to help.

[GaryR]

Glenn - these are from this post courtesy of Len (BoxsterGT) -
Fuel Hoses - 911SC Tunnel to Motor

[aigel]

Fuel lines - nice job! Welcome to the brotherhood. Haha!

My fuel line in the SC started leaking in the 5 days I had it parked, waiting for the new owner to pick it up! Total PITA to replace, but I did it for the new owner and delayed pickup until it was fixed.

I always take a lot of pictures disassembling. They can be worth their weight in gold (or bitcoins?) later.

G

[DaddyGlenn]

Thank you. I've got the info I was looking for.

[gregwils]

I had my motor and front suspension out a couple of winters ago and decided to bite the bullet and swap out the thru-tunnel lines as a 'while you're in there' project. Thirty year old rubber carrying fuel doesn't seem like a good idea.

[GaryR]

All this tunnel lines talk and now i'm adding this fun project to my list while my engine is out..

[DaddyGlenn]

It has been an extremely slow year. Not a whole lot going on in the garage but I am back at it. Disassembling the CIS, just a bit, to clean and replace gaskets, injectors, anything made of rubber.

[mcaterino]

Nice to see your progress. Keep it up!

Mike

[puddy]

Did you get those fenders painted yet?

[DaddyGlenn]

No paint on the fenders yet. But I have patched most of the rusted areas on them. I'm trying to get the engine and transmission together and back in the car so I will have room in the garage to fabricate a small paint booth.

[scarceller]

Nice to see progress again! Keep up the good work, the reward is near!
Love the color!

[DaddyGlenn]

Need some help... I damaged one of the fuel lines while removing the engine. I have misplaced the broken piece, but I have the ends and some replacement stock. My problem is, I have no idea how long it should be.

Would one of you kind folks (with a similar SC) measure this line on your car and share your findings?

The line goes between the engine and the bottom of the fuel accumulator and is marked in yellow below. I'm sure it has a name. I just don't know what to call it.

[Tremelune]

Just chiming in to say wow. True dedication on the bodywork. I plan to strip and rust-proof my interior, and I do not look forward to it at all.

[DaddyGlenn]

Yesterday, I dropped off some parts to be powder coated. They should be ready next week.

Then I dropped of another set of parts at another place to have them plated. Plated with cadmium. I thought nobody did cadmium anymore and I was going to have to settle for yellow zinc but these guys do cadmium for about the same price as zinc. But, since they are a small shop, it will take several weeks for the plating.

I'll post pictures when I get the parts back.

[CBRacerX]

Great project and your determination is impressive. Best of luck getting it done. When you're back on the road and everything is all that it should be you are going to have the biggest smile anyone's ever seen.

[DaddyGlenn]

Parts back from powder coat!!





And here is the valve cover transformation....

De-greased


Sand blasted


Powder coated

[DaddyGlenn]

And then a little special treatment for valve covers....

Lower cover


Flip upside down on a sheet of 220 on a flat surface


Slide it back and forth gently until it looks like this


A slightly different approach on the uppers

Tape them up


Then I used a small sanding block with 220 (very carefully) to remove the unwanted powder coat



Remove the tape, rinse the dust off and...