Hi Von,

I do indeed have the old plate but it is in bad shape. The edges around the holes are broken and there is a big dent in the middle. It is also the wrong paint code!!

Just thought I would post a quick update and laundry list remaining to finish the project.

This Thursday Peter is going to come over and we will try to install the headliner!!
After the headliner is done I will have the following tasks to complete before the Rat is back on the road:)

Finish Thermocoustic liner install
Install fuel tank vent system
Install quarter windows with new seals and cleaned and polished trim
Address issues with lights on driver side rear
Install carpet and interior ( I will have the seats refinished at some point down the road)
Install door seals
Finish work on the dash and install
Bleed brakes
Install S rocker trim
Install front and rear glass
Clean up the engine bay
Put on hood crest :cool::D
Get new appraisal and alignment

hey - can I get you guys to weigh the headliner and the metal bows on an accurate scale?

Inquiring Minds WANT to Know...

Day 84: Today Peter and I were able to install the headliner and finish the sound deadening material on the passenger side. Thanks for all the help Peter. Without you and your awesome T-shirt the headliner would still be lying on our guest bed :-) Sorry Randy I did not weight it before it went in as I do not have an accurate scale at home. I have the old headliner and could weigh it at the university without the bars if that helps you. Overall the install went great and I would like to thank everyone that posted regarding the headliner install. Using the excellent write up and video below the task was a 3 out of 10 so don't be afraid to tackle it yourself. As long as you have plenty of clips, 4 hands, Weldwood Contact Cement, patience, and a good quality headliner from Pelican this job is easy. Peter and I took about 3 hours to get the headliner installed and I still need to fold and glue the excess material over the lip this weekend.

http://forums.pelicanparts.com/porsche-911-technical-forum/666633-part-1-headliner-install-dont-scared.html

911 68 headliner fitting with Gary Cook.wmv - YouTube

Here are some pictures of the install

http://forums.pelicanparts.com/uploa...1354247784.jpg
http://forums.pelicanparts.com/uploa...1354247807.jpg
http://forums.pelicanparts.com/uploa...1354247846.jpg
http://forums.pelicanparts.com/uploa...1354247873.jpg
http://forums.pelicanparts.com/uploa...1354247906.jpg
http://forums.pelicanparts.com/uploa...1354247936.jpg

Great work!

I've gotta do this after I've finished welding in the drivers floorpan, and seeing you give it a 3 out of 10 has really encouraged me!

Also gonna use the Eastwood sound deadening, they sell it as a complete kit here in Blighty

It's got damn cold here in the UK this last week, but I'll wrap up warm and keep you posted on progress

Still not had the time to start my own thread!

Keep up the fantastic work!

Tony

Congratulations on getting your headliner in! It looks great! How long until the maiden re-voyage? When finished, you should drive up to Tampa for a Cars & Coffee at either the Dupont Registry (huge) or Reeves Import Motorcars (small compared to Dupont but growing)... You have a place to stay at our house if you ever do.

Jeremy

Thanks Tony! You are going to need at least 25 square feet of the Eastwood Thermocoustic Liner (5 packages). I ended up with 4 extra pieces but I did not have to do all of the rear deck. I put a bunch up on the roof that the orginal roof sound pad did not cover to quiet things down overhead. Once you have your thread going please post it here so everyone can have a look. Can't wait to see your project!

Hi Jeremy! Thanks for the encouragement. The maiden re-voyage is currently scheduled for mid to late January. My wife and I will be in New Mexico for two weeks during the holidays for a much needed break with family. I hope to learn how to rebuild an engine from Obi Wan when we are there:). Thanks for the invite. I will send you a PM when I am getting close to finishing up as we need to have a coffee (read beer) soon.

I made some fantastic progress today. I was able to finish the headliner and got vinyl installed on all of the pillars. I was also able to install the chrome trim at the bottom of the quarter windows. Currently my wife and I are getting ready to go and swim with manatees so I will post pictures tomorrow!

The headliner looks really nice. Thanks for mentioning that it's not too terribly difficult. Looking forward to putting mine in...whenever that may be. Anything tricky about putting the vinyl back on the pillars? I took many photos of where the folds in the vinyl were when I took mine out. It looked like it would be easy to put it back...but there are many things about my restore that I thought would be easy when I started. Like....umm....currently I'm stuck drilling out what seems to be thousands of spot welds to replace the rear crossmember. The spotwelder who put on my rear crossmember must have really loved his job. He went nuts with them. What a pain in the...

I weighed my old headliner and it was exactly 1 lb.

Hi Von,
Putting in the vinyl was not tricky at all. Once you get good at using the Contact Cement and make sure to time the glue everything is straight forward. I would give installing the vinyl trim a 2 out of 10. Having the old pieces as a template was very helpful for cutting things to the correct size. Good luck with the spot welds:(

Day 85 Finishing up the headliner: I was able to finish up the headliner and trim all of the excess. I was also able to install all of the vinyl trim on the A and B pillars. Overall, the job of the headliner and the vinyl trim was not that difficult, only time consuming. I have a few spots that I am going to hit with a steamer but overall I am really happy. If you are patient you can do this no problem. I really don't understand what everybody is afraid of. Here are some pictures from finishing the headliner install and installing quarter window trim.

Using the old vinyl trim as a template
http://forums.pelicanparts.com/uploa...1354547287.jpg

Lower driver B pillar vinyl glued into the lip and waiting for the contact cement to set to finish the job
http://forums.pelicanparts.com/uploa...1354547334.jpg

Finished upper B pillar
http://forums.pelicanparts.com/uploa...1354547407.jpg

Finished lower B pillar
http://forums.pelicanparts.com/uploa...1354547448.jpg

Top of the doors installed
http://forums.pelicanparts.com/uploa...1354547521.jpg

Day 85 continued:

Driver A pillar vinyl trim completed. I left the clips on overnight to make sure the glue was set
http://forums.pelicanparts.com/uploa...1354547606.jpg

Quarter window trim installed. I used the Terostat ribbon to seal the chrome trim and made sure to place the spacers in the correct spots. The thinnest spacers start toward the rear of the car with the thickest spacer being closes to the door jamb. Towards the rear of the window I only used one thickness of Terostat ribbon. At the middle I used two thicknesses and in the front I used 3 strips stacked up on top of each other. I also made sure to put Terostat on the lip that the chrome trim fits over.
http://forums.pelicanparts.com/uploa...1354547661.jpg

Test fitting the interior vinyl :D:D Once the carpet goes in all of this goes back in as well !!!!:):D

http://forums.pelicanparts.com/uploa...1354547918.jpg


After working on the car for about 8 hours I was sick of "Rat" work and went and picked tomatoes instead. Having a garden is one of the most relaxing and rewarding things a man can do:D:cool:
http://forums.pelicanparts.com/uploa...1354548025.jpg

I am getting ready to install the quarter windows with new seals and have been doing some research. It looks like it might be a pain but the following two links should help

Rubber Seal

http://forums.pelicanparts.com/porsche-911-technical-forum/495432-quarter-window-seal-pop-out-window-installatiion-question.html

Fitting pop out window to later 911s
http://forums.pelicanparts.com/porsche-911-technical-forum/347620-install-pop-out-rear-quarter-windows.html

If anyone is interested I have my old headliner and the old vinyl from the A and B pillars available. These came in really handy as a template. I could include all of the clips I used for the headliner and ship the entire thing as a "package" for headliner and vinyl install. I hope that somebody can use this stuff to give life to another 911 now that I am done with it. Please PM me if you are interested.

Day 86 Gas tank vent system installed : Today I was able to install the gas tank vent system using the exact setup from 69.

Vent tank
http://forums.pelicanparts.com/uploa...1354555519.jpg

While I was inspecting the area where the tank goes I found an old original rubberband used to hold the tank in place. The rubber band was really brittle so I replaced it with some thin bungee cord.

http://forums.pelicanparts.com/uploa...1354555710.jpg

To install the vent tank I needed to remove the hood shock on the drivers side. To hold up the hood during this operation I used three tubes from my shop vac;)
http://forums.pelicanparts.com/uploa...1354555817.jpg

At first I installed the vent tank using clear vinyl tubing for both the inlet and the outlet. The inlet hose from the gas tank kept kinking so I replaced it with a rubber hose. The picture below shows the original install with vinyl tubing and the kink.
http://forums.pelicanparts.com/uploa...1354555937.jpg

After I installed the tank I plumbed the brake reservoir vent line and the vent tank outlet line into a T fitting. I found a really clever fitting at ACE Hardware that allows you to fit different size hoses by cutting off smaller fittings until your correct size is reached.
The fitting
http://forums.pelicanparts.com/uploa...1354556102.jpg

Cut and installed
http://forums.pelicanparts.com/uploa...1354556142.jpg

The next step was running an outlet hose from the T down through the plug above the windshield washer motor.
http://forums.pelicanparts.com/uploa...1354556206.jpg

The final step was running the car for about 15 minutes to ensure that the tank was being vented adequately. It was and the Rat ran like a champ with the new vent system:D.

thanks! that was just the headliner, not the metal bows, right?


PS - don't use regular vinyl tubing for the emissions system; get vapor rated hose (looks like regular vinyl)

It was just the headliner. It might weight more than new because it had a ton of old dirt on it. Thanks for the tip about the vinyl tubing. I got the heavy duty stuff from Ace Hardware and will double check next time I am there. Who am I kidding? I live there ;)

sure - find a hose shop for the good stuff

I think I will use a coat hanger to estimate the wt. of the bows. How many are there on your car?

I am just curious if the felt material used on the typ R saved any wt. ...