It is alive!!

Still much to do. But this made me :D http://forums.pelicanparts.com/support/smileys/wat3.gif:D

Woo Woo!

I've been following your thread for years. Those seats are stunning. Congrats on firing her up.

Thanks Tim. I wish it hadn't taken so many years. But sometimes life does get in the way.

Getting the engine running has been a huge motivator. This weekend I moved to the front of the car and got all the under fender stuff installed.

I installed the horn upgrade kit from our host. I haven't tried it yet.

http://forums.pelicanparts.com/uploa...1451865656.jpg

Ran new hoses for the windshield washer system and got the tank installed. I'll have to fabricate a new mount for the washer pump as I had to remove the old one to install the oil cooler duct. I decided to disconnect the headlight washer system, for now. I didn't work before so I won't miss it. I'll add that to the things to fiddle with after it is back on the road.

Today, I turned my attention to the front valance. And I took time to snap a few pictures for you.

This is where I started this morning...

http://forums.pelicanparts.com/uploa...1451865239.jpg

I temp mounted the valance using small c-clamps. Marked a couple spots to drill holes in the bumper for the mounts. Off with the valance, drilled the holes then added a strip of thin neoprene to serve as a buffer between the valance and bumper.

http://forums.pelicanparts.com/uploa...1451865472.jpg

Then the valance went back on using a couple M6 bolts through the bumper with fender washers on the fiberglass side. While I was lying on my back trying to hold the valance and install the bolts, I realized I should have just drilled and tapped the bumper instead through bolting it. I am not 100% comfortable with spreading the force over just the two attachment points in the from (either side of the oil cooler) and where the sides connect to the fenders. So I will add additional connection points across the bumper. Drilled and tapped, of course. And after the heck of a time I had getting the valance attached, anytime it needs to come off in the future, I will remove it and the bumper as a unit. It will be much easier that way.

This bolt was a real challenge.

http://forums.pelicanparts.com/uploa...1451866179.jpg

Valence installed

http://forums.pelicanparts.com/uploa...1451866313.jpg

So with the valance on, I put the screen over the oil cooler inlet and installed the accordion rubber pieces.

Had to trim the valance on the passenger side a tad. The pelican I purchased the valance from had already done the driver's side.

http://forums.pelicanparts.com/uploa...1451866570.jpg

Had to run out to Home Depot to get some hardware to install the screen and really fiddled with that for a good bit of time. I'll grab some black model paint and hit the hardware. Not real jazzed with the silver hardware on the black screen.

Here is the end of day picture..

http://forums.pelicanparts.com/uploa...1451866587.jpg

Now I have to try to remember how the lights and turn signals go in.

Way to go Glenn, almost home!!

Thanks Gary!

I guess an update is in order.

I've made a bit more progress. Had a setback while installing the headlights. did something stupid and had to replace one of the lenses. That was a task I hadn't done before but a relatively easy one, once I had the part. I've got some electrical gremlins in the turn signals. I'm thinking it is a relay, but I have just added that to my list of things to troubleshoot later.

I've pretty much finished at the front of the car, minus a couple annoying details. And now I am focused on some under car items.

Today, I've connected and adjusted the clutch cable and was about to install the axle assemblies when I discovered that I hadn't purchased new bolts and washers. Which is why I am here at the computer.... to spend a little more.

I think next on the list for today will be to assemble and mount the rear bumper and perhaps the engine lid.

Here are a couple shots of where she stands now.


http://forums.pelicanparts.com/uploa...1455993073.jpg


http://forums.pelicanparts.com/uploa...1455993097.jpg

Great work Glenn: I have been following this from the start. You are keeping your project moving forward way faster than I have - very impressive work. Great attention to detail; love the color, it is a great car. Congrats, it looks like maybe the finish line is not that far away.

what an awesome job you've done .... Very inspiring!

Look what just came back from Allegheny Metal Finishing....

http://forums.pelicanparts.com/uploa...1462410528.jpg

http://forums.pelicanparts.com/uploa...1462410561.jpg

Powder coated satin black. Tires get mounted on Friday.

Nice work

Looking at how many years this project has gone on I wondered if some of us just like working on projects? 6 years is a long time, but why do we take on these projects? I mean, it's a car, and do we get the most enjoyment out of driving it or working on it? I love driving my car, but I also love working on it. But sometimes I think we let projects take large chunks of our lives. Sometimes I have to stop and tell myself not to do it... Not just with cars, but with things around the house as well. I love projects, but the satisfaction and frustration is a love hate relationship. After all this work I really hope you get to enjoy driving it. Hopefully you won't get it so perfect that you won't want to drive it.

I have been working on it. I just haven't taken the time to share any update. So this is where I am. With the completion of the carpet install today, my list of big things to do is done! http://forums.pelicanparts.com/support/smileys/wat3.gif

Now I just have a long list of little things to correct or complete. Nothing on that list is necessary for me to drive it.

It is registered. I've reactivated the insurance and all it needs now is an alignment and to pass the state inspection.

Here are a few pictures:

http://forums.pelicanparts.com/uploa...1474847874.jpg

http://forums.pelicanparts.com/uploa...1474847924.jpg

http://forums.pelicanparts.com/uploa...1474847956.jpg

http://forums.pelicanparts.com/uploa...1474847983.jpg

Love it!

Fantastic job Glenn. I remember when you started this thread... a few years ago now... way to stick with it! It looks really great!

Happy driving!

Tom

Thank you gentlemen. I have owned the car for about 12 years and this reconstruction has taken up the last half of that time.

I have learned so much. I could not have do it without the encouragement and tutoring of those on this board. The next time I take on a build like this, it will be easier and take much less time.

Looking great! Well done getting to the 'finish line"

Hats off to you Glenn for amazing perseverance. Most projects like this get sold as a 'project'. Quite an accomplishment for a single person.

looks greeeeat glenn...!! nice color combo & contrast...
tell us how she runs after you are on the road for a bit and get a minute...
way to see the project thru...!!! enjoy... bob

Greg is that a shot over the bow in regards to Glenn being single? Ha. Definitely more difficult with a wife or kids. Great job no matter the circumstances.

Yes, I have a wife and 4 kids (now 14, 16, 17 and 20) and they each did their share of keeping me away from the project. And I had several self-inflected household projects, too. But I can be pretty tenacious.

Nick work! I have loved following this thread. The car looks awesome!

I agree with what everyone is saying. Really awesome thread and overall documentation of the rebuild. I can't say that I'm surprised that there were a few unsuspecting fixes; a proper rebuild can't go totally smooth, but I'm glad that you got it done. In case you're wanting to add any final touches, we have a newly revamped Accessories section on site. Let us know if you find any useful and best of luck with your future builds!


-Dmitry

Geez, Dmitry! How many more thousands of my dollars do you guys want? I've probably spent more on parts from Pelican than I did purchasing the car.

Glenn,

My apologies if the post sounded pushy. I just wanted to alert the users of our new section. We GREATLY appreciate you being such a loyal Pelican customer.


-Dmitry

Annnnnnd, I'm legal.

http://forums.pelicanparts.com/uploa...1475709574.jpg

Congrats Glenn

You've come a helluva long way over the past 6 yrs. This has been a great thread.

Cheers
JB

Bringing this thread back to life. The car has been my daily driver for many years now, except when there is salt on the roads. But, it is time for it to go to its next owner. I'll be cleaning up some of the age spots, and bumps and bruises it has accumulated, then putting it up for sale. Stay tuned for updates.

Looking forward to the updates! Shame it's time for a new owner but at least it served you well for many years!

Step 1: Solve warm start issue.
 

I've had warm start challenges for a while now but a couple weeks ago, it stranded me.

Scenario: 1 hour drive down the highway on a hot summer day. After sitting for about an hour, it would not start. The engine turned over but would not fire. I noticed I did not hear the fuel pump turn on with the key in "run", as I usually do. And I could not tell if it turned on in "start". I opened the air box and lifted the air meter to see if the pump ran but could not hear anything. I tried starting it several more times, with no luck. I towed it home and put it on the lift, figuring I had lost the fuel pump or relay (I did not have a jumper or spare relay with me).

Testing: I applied power directly to the FP and it ran. Lifting the air meter also caused it to run. So, I tried starting it. It started.

Today, I measured the fuel pressures.

Temp at the Warm Up Regulator was 21.8C/71F
System Pressure - 4.8 bar/70 psi
Cold Control Pressure - 1.35 bar/20 psi
Warm Control Pressure - 2.9 bar/42 psi (after 5 minutes)
Residual Pressure - Dropped to 0 after 13 seconds

No fuel leaking anywhere. So I am losing pressure at either the check valve (built in to the fuel pump) or the Accumulator.

My accumulator is the type with 3 hoses. If I remember correctly, the hose at the bottom should only see fuel if there is an internal failure of the accumulator. When I pulled the bottom hose off the accumulator, a good bit of fuel came out.

Diagnosis: Failed Accumulator. The only thing it doesn't explain is why lifting the fuel meter when I was stranded did not trigger the pump. (Or maybe it did, but I couldn't hear over the ambient noise and did not run it long enough to get the fuel pressure up.)

Any other opinions or thoughts?

"My accumulator is the type with 3 hoses. If I remember correctly, the hose at the bottom should only see fuel if there is an internal failure of the accumulator. When I pulled the bottom hose off the accumulator, a good bit of fuel came out."

This was proven to be incorrect, fuel can and will be present in the bottom fuel line on the accumulator with a properly functioning accumulator. How much flows out may be debatable. The way to test is to apply a vacuum and see if it holds, I removed mine for this test. Tony has shown several methods to test.

Phil

ahh911 is correct. A more accurate way would be to take the line off the bottom of the accumulator and plug it. Here is a good thread dealing with possible issues and testing.
http://forums.pelicanparts.com/porsche-911-technical-forum/1159640-fuel-pressure-testing-system-pressure-cold-control-pressure-residual-press-0-a-3.html

As for the fuel pump, could the fuel pump relay be failing?

Did a vacuum test on the fuel accumulator. It had a leak. Replaced it and now the system holds pressure as expected. I also replaced the fuel pump relay, just in case.

Now I have to go solve a shifting issue in the 944 race car.

Re fuel in the bottom of the accumulator, to be clear:
There will be some fuel there because that is the return line, and some fuel will migrate there from the return loop. However, if you remove the line, and then RUN THE PUMP, you should get NO fuel leaking out (be sure to plug the return line when running the pump). If fuel leaks out, the FA is bad and must be replaced. After you remove it from the car, try the vacuum test too.