SC Project

[G450X]

[QUOTE=MetalDoc;6445405]For the non-believers, here's a pic of the odometer (new gear ordered). The PO loves Porsches. He claims that he only replaced the clutch at 250k and the heads + engine was never taken apart. I've got instructions for 1 quart Marvel Mystery oil every oil change and a capful of it in every gas tank. I thought about taking the engine apart but I decided too many other irons in the fire. I drove it for a week without 1st gear and the engine ran like a sewing machine. I replaced all the seals and put in new tubes from the heads to the block.

I'm one of the true SC high mile "believers." My cousin had a '78 that he ran the &%#!! out of, sold it to a friend who ran the $#@!* out of it for another 100k miles, and is still seen around the area (mileage unknown at this point). There are way too many high mile SC stories floating around for them all to be BS....

Have fun with the build, SC's are great 911's - and at bargain prices these days.

[MetalDoc]

Hi,

It's been a while since I made any progress getting my car back together. First I'll post a few pictures from my trip to Austria, where I went to a Porsche museum in Gmünd, Austria. At the end I'll post a small write up of changing from the throttle linkage to a cable I bought from Pegasus.

Early 911 Engine


Lets go racing




Now for the throttle cable install. I needed to do this to connect to the throttle linkage on the Jenvey ITB's. There are some threads talking about replacing the linkage with a Morse cable for push-pull operation, in my case I just needed a pull so I purchased a 108" of teflon lined jacket and about 125" of cable with 10-32 threads on one end. This cable is too long and it will be cut to size once the engine is installed. It turns out the 10-32 thread fits the 5mm metric ball end at the throttle. The thread engagement is good and I used a locking nut plus loctite to secure it. It's a little scary to pull out the original throttle linkage out of the tunnel, once it is out I don't think you can get it back in easily. I needed to fabricate an end bracket (near the gas peddle)that was attached to the tunnel with 10-32 machine screws, see pictures below. The bracket protruded 1" from the wall inside the tunnel and when installed I found out the clutch cable rubbed on it. To eliminate the rubbing the bracket was machined to 0.750". For me the most difficult part was getting the screws to engage with the bracket. Under the dash board there is not much room to work and it was hard for me to get the screws into the threads I put in the bracket. Today I finished this part and I probably won't want to change things for a long time, if ever.

Throttle cable end with bracket before machining to final size.


Picture of throttle linkages before install

[MetalDoc]

Still moving slowly along. Installed Damplier Pro to the roof and positioned the headliner. Does anyone know where to get foam for the roof vent? The foam in there is crumbling apart.

[MetalDoc]

Hi, It's been a while since I worked on the car. Since the last post I have not done too much. I took apart the front sport seats and then rebuilt the foam that was torn and sagging. To finish them I bought some leather seat covers and installed them. Today I finished the headliner and installed the windshield. To get the aluminum trim in place I found it was best to use some pinch clamps I use for woodworking. I didn't see a need to use any soapy libricant to get the windshield to seat right. I used two wraps of ventian blind cord in the gasket groove, placed the windshield centered in the opening and it seated in the window frame. Then waited for my son to come home before I pulled the cord out. I had him lean on the windshield in the areas, from the outside, while I was pulling out the cord. It took about 15 minutes to get gasket seated on the windshiel, 30 minutes to install the outer trim in the groove, 30 minutes to center the windshield in the car, and 10 minutes to pull the cord out. I included some pictures below.

Paul

Before install

Clamps used to get the trim in the groove

In position

Installed

[MetalDoc]

Hi,

I started on the rear quarter windows. I figured out how to stretch the gasket on, but I'm having trouble installing the aluminum trim pieces. Does anyone have any suggestions on how to get them in? So far no luck.... kinda a pita campared to the front windshield.

Thanks in advance for your input.

Paul

[Jeff Burger]

Originally Posted by MetalDoc

For the non-believers, here's a pic of the odometer (new gear ordered). The PO loves Porsches. He claims that he only replaced the clutch at 250k and the heads + engine was never taken apart. I've got instructions for 1 quart Marvel Mystery oil every oil change and a capful of it in every gas tank. I thought about taking the engine apart but I decided too many other irons in the fire. I drove it for a week without 1st gear and the engine ran like a sewing machine. I replaced all the seals and put in new tubes from the heads to the block.

Paul


I showed the PO the pictures of the engine last week. He keeps asking for the steering wheel. I'm not sure what he is going to do with it? He is in his 70's and since he sold me this 1 1/2 years ago he has been driving a scooter. He told me he walks a lot in the winter. He is glad to see that I'm working on it.

Jeez give the steering wheel to him !

[Kool-aid-82]

On the quarter windows I soaked the seal in hot bath water, used clamps like you have and cursed - allot.




The trim will pop out if not perfectly shaped.

Took a couple of tries to get everything installed right, hot water makes the rubber softer. I then used Dish soap and a helper on the outside, rope on the inside.

But it can be done.

Nice color on your car.

[APachon71RN]

I love where this is going but more so from where it began.

~Andy

[MetalDoc]

Billy,

Thanks for the suggestions. After sleeping on it I figured I needed to press the trim in with different wood clamps. One went in after 10 mins and the other quarter window took about 45 minutes. I spent the last hour trying to pull it into the opening with two wraps of the cord. Afterwards, I could see the top half didn't pull over the lip. I am going to re-wrap and try again after lunch.

Jeff, My friend Darrell can have the wheel anytime he wants it. When it is done Darrell will have the first ride and is welcome to drive it. After I bought it he gave me his Porsche jacket off his back. Then he bought himself another one.

Paul

[Jeff Burger]

Originally Posted by MetalDoc

Billy,

Thanks for the suggestions. After sleeping on it I figured I needed to press the trim in with different wood clamps. One went in after 10 mins and the other quarter window took about 45 minutes. I spent the last hour trying to pull it into the opening with two wraps of the cord. Afterwards, I could see the top half didn't pull over the lip. I am going to re-wrap and try again after lunch.

Jeff, My friend Darrell can have the wheel anytime he wants it. When it is done Darrell will have the first ride and is welcome to drive it. After I bought it he gave me his Porsche jacket off his back. Then he bought himself another one.

Paul

outstanding !

[MetalDoc]

Here is a quick update. I have been working on painting the engine compartment. Meanwhile, I replaced all the tubing in the windshield washer system and while messing around up front I noticed a corroded wire on the fuse block, while trying to remove it the corroded screw broke so I had to order a fuse block. The kind I am installing is with the plug in fuses from Chief Electronics. Today I took the shocks out and I was disappointed because it looks like the shocks are toast. I can push them back and forth by hand. It looks like I need to replace the rears and probably the front.... I gueass I'll be taking some more parts off the car. One step forward and one step back.

Paul

[garment]

Where did you get the leather seat covers from? Can you post some pics?

Great build thread!

Hi, It's been a while since I worked on the car. Since the last post I have not done too much. I took apart the front sport seats and then rebuilt the foam that was torn and sagging. To finish them I bought some leather seat covers and installed them. Today I finished the headliner and installed the windshield. To get the aluminum trim in place I found it was best to use some pinch clamps I use for woodworking. I didn't see a need to use any soapy libricant to get the windshield to seat right. I used two wraps of ventian blind cord in the gasket groove, placed the windshield centered in the opening and it seated in the window frame. Then waited for my son to come home before I pulled the cord out. I had him lean on the windshield in the areas, from the outside, while I was pulling out the cord. It took about 15 minutes to get gasket seated on the windshiel, 30 minutes to install the outer trim in the groove, 30 minutes to center the windshield in the car, and 10 minutes to pull the cord out. I included some pictures below.



Paul



Before install



Clamps used to get the trim in the groove



In position



Installed

[MetalDoc]

Hi,

I got the seat covers from GAHH. I am sure there are many places to buy them, including Pelican. When I got the estimate from the upolstery shop, I decided to give it a try. It took me longer than I thought it would. The major difficulty is getting the seat pads back to the original shape and reinforcing them so they will hold up. The seats turned out good for my first time. I am still trying to remove some wrinkles. I tried hot, damp rags to get them to shrink but no luck yet. Next option is to try steam.

Paul

[MetalDoc]

Here is the link to questions I have about painting the engine compartment. My main question right now is how to keep the wires out of the way while painting.

http://forums.pelicanparts.com/paint-bodywork-discussion-forum/849040-will-paint-stick.html

[bryant4]

you can use aluminum foil to wrap your wires and cables before painting. Works very well and is easy to remove.

[RSBob]

Giving the wheel back to the PO is the biggest favor you can do for yourself. If it is a true wood wheel, in the event of an accident you don't want to be any where near something that can break apart and skewer you like a shi'a kebab.

[PorscheAmateur]

Looks like a great project and I'll definitely be following this thread. Goes to show how driving your SC is the best option for longevity.

[MetalDoc]

Sucess! I managed to pull the wiring harness out of the engine bay without removing any plugs etc. It would be nice to know where to get the foam strip that is jammed in back there. The old one is falling apart. It is about 2 inches thick and runs the length of the cross member.

A note on the wheel. I don't plan on keeping it on the car. My friend Darrell is getting it back. I'm looking for a suitable replacement.... not sure what that wil be. The stock ones look too plain.

[MetalDoc]

Sent out oil tank for ultrasonic cleaning. On return painted the oil tank and engine compartment. Since the shocks were shot, I decided to upgrade the suspension. The parts came in last week and this weekend I started getting ready on the front end.

Paul