more embarrassing admissions-suspension upgrades

[david c.]

Hi guys,

Since we've been telling embarassing stories on the board lately, here's one:

Some of you may recall that I'm engrossed in a complete suspension upgrade/refurbishment of my 912E.

This includes new sway bars, new Bilstein sport shock/struts, 21/26 t-bars, aftermarket adjustable spring plates, turbo tie rods-and, as it turns out, replacing all the original rubber front suspension bushings with poly bushings.

But, I remind you, I am a law student with no formal mechanical training and an unheated, drafty detached garage. So, although this saga began MONTHS ago, I am still without a car!

The funny story regards the front sway bar. Since the 912E came from the factory with a puny little front sway bar (and no rear one at all) I decided to go with the installation of a 22mm Weltmeister "through body" front bar. Sounds really manly right?

So, a few weeks ago I get around to reading the installation instructions for the mounting brackets after having ground off the original brackets way back in February.

The directions say, basically, to drill a hole in each A-arm and bolt the brackets to it.

What?

Drill a hole through my stamped steel A-arm? This sounds like rust heaven? So begins the genesis of the "big idea". I began thinking-why not have the mount welded onto the A-arm like the factory does it? I had shiny metal from grinding off the old mounts anyway- welding seemed logical enough at the time. I decided to go this route. This required removal of the A-arms because I don't own a welder. Now, removing the suspension is scary to a guy with no idea what he's doing.

Weeks later I was still trying to get the damned ball joint pinch bolt to let go of the bottom of the strut housing. You see, my simple mind didn't want to have to remove the entire strut housing, brake lines, etc. I tried heat, big pry bars, tons of penetrating oil, beer, anger and objectionable language more beer, etc. No dice-wouldn't budge on either side.

Finally, I gave up, removed the whole damned front suspension in two pieces from the top nut on the strutsto the A-arms. I dropped the A-arms off at a local garage owned by a friend. He's going to weld the mounts for me and remove the ball joints. This should be done tomorrow. Finally, I can begin reassembly!

My "big idea" resulted in ruining: two perfectly serviceable ball joint boots, one wheel bearing cap which I had to beat off with a sledge hammer, most of my knuckles, etc. I hadn't planned on replacing all of my front bushings, but I'm going to do it now since everything is apart anyway. Thanks to Chuck Moreland for the humorous tech article on the removal job-I did that over last weekend.

All this while I should be studying for exams...

Later,

David

[83911sc]

Dave-

thats priceless - as I was reading your post I could swear that you were writing on my computer because that is the way my projects tend to "develop". Good luck with the uprades.

Adam

[marcesq]

David:

If its any consolation, you can practice law for 17 years and still have moments like that.

Good luck with the exams.

[david c.]

Thanks for the empathy!

Last night was the drilling of holes through the body for the new sway bar.

For those of you who have done this, you can relate to the faith it takes to start drilling holes with a hand-drill through the body of your pride and joy.

NO amount of directions, preparation, careful template drawing, pencil marks or whatever makes is easy to take that leap. I had to feed the bar through the hole (before I ever got around to installing the bushings and reinforcing brackets) just to convince myself that the holes lined up!

Later,

David

[avi8torny]

A lawyer who has some grime under his fingernails because he works on his 911 at night would be my first choice if I ever needed one.

[marcesq]

TD:

How would you feel about one who works on his evenings & weekends (except of course when he is ripping through the countryside with other Pelicanites on Saturday mornings).

Thanks for vote of confidence.

[Moses]

Sue yourself for gross mechanical incompetence.

For damages, award yourself a six-pack of your favorite brew. Share with some friends and tell the tale.

I love reading posts like yours because EVERY mechanical adventure I undertake has more twists and turns than HWY 1. Somehow at the end of it, our cars usually forgive us.