Torsion bar access hole........
 

This is the picture of the access hole for '87 Carrera with G-50. The hole is approx. 4 inches across:
http://forums.pelicanparts.com/uploa...1333857444.jpg

This is another picture from a '78 SC with 915 transmission. The hole is much smaller and measures about 2.5 inches across:
http://forums.pelicanparts.com/uploa...1333857536.jpg
Tony

Hi guys. mission succeed.

To explain the original problems. The t-bars were already loose from the plates/tubes. The problem was the the holes on body panel was a little too small, but I enlarged it a little bit and the tubes went through.

Then the second problem was t-bars and the tubes are too long to make it off the car, even when the tubes can slid through the holes all the way. Even if I cut the body panel, bottom of the holes, there will be not enough angle for the t-bars to come off the tubes.

Whatever my t-bars/tubes are, I think it's too long for the normal carrera. After installed, the t-bar came out around 1/4" to the end of the tube, and the tube is measured 9" long from the spring plate to the end.

Lesson learn.

- Maybe it's the 87-89 built. There is a blockage in the middle of the car. The t-bars won't be able to go through from side to side, as djdsc suggested. And if you knock/hammer the t-bar in, it will be stuck. Ask me how I know. Lucky for me that I only knocked it slightly on one side to test the water, and Draco could be able to pry it out with a vise grip and a big screw driver.

- If you are in this situation, the only way I found that works is pop out the cap at the end of the tube and slight the t-bars out, as HFR, boyt911sc , and D911SC suggested. It's hard, but it's doable. First, I used carbide drill bit to cut around the tube end and pried the caps off. It'll take time, pry at different angles, it will come off. The inside end of the t-bar is smaller in diameter compare to the outter end, so the t-bar can be slid off the tube and came out as D911SC Assumption.

Everything is in place now and that was the end of the day, actually the night. Just have to do ride height again, and alignment when I receive the toe's nut/bolt from Group911. Maybe next week.

Thanks everyone, alot. and sorry if I missed anyone else names/suggestions.

Glad to hear you are making progress, but I wouldn't suggest anyone follow the path of cutting the cap off the spring plate. That cap serves the purpose of keeping the torsion bar from slipping out of the spring plate.

Now that you've cut the cap out, you'll need to devise a new way to retain to torsion bar.

Having the correct cover plate on the body is the way to do this right. It is the way the factory did it.

Agree. I didn't cut it off completely. I more like grinded it arpound the outer edge and pried it out. It will go back in, but might not be very tight. Will have to figure the way so it can stay there tight, just as if you couldn't pry your off, without grinding it. Maybe I'll give it several points of weld.

There's a similar discussion going on over here on Impact, BUmpers at the moment for information. The option suggested by Nick Moss may work for you
Board Message

Regards

Ian

Alright, now I am moving to alignment and have the first question. it regards the 2 last bolts which tight the spring plate to the big banana arm at the hub. Theose 2 holes on the spring plate is not rounded, meaning they have some more adjustment to pull the hub forward or push it backward. When tighten these bolts, do you push the hub all the way to the rear, or pushing it to the front, or leave it whereever they want to be? When I leave it, on one side, it's at the rear, and the other side is at the middle of the hole. I feel like I should push them both to the rear if I want the least toe, and to have both wheels at the same length. Am I correct?

They are slotted so that the toe eccentric bolt can pull or push the banana arms as needed.
If you marked the out line of the spring plate on the banana arm before you did the bushings set it there to start with.

so I should tight these lock nut/bolt (from spring plates to banana arms) firs before I adjust the toe/camber bolts?