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Let us know when the motor back in & send the biggest pics you can of the job done.Take care & be safe when installing it back

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Old 10-15-2020, 08:54 AM
  Pelican Parts Catalog | Tech Articles | Promos & Specials    Reply With Quote #401 (permalink)
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Merci bien Ernie, thanks Bob and Patrick.

The car is on a scissor lift and the engine is on a lift table, a bit overkill in terms of adjustability, but weíll see.

Just now I realized I didnít have a clutch alignment tool; in the past Iíve used a deep socket and masking tape to get the right OD but for $5 itís be goofy to thusly bugger around so my local CarQuest has one coming tomorrow morning. My back could use a break anyhow. Hopefully with the clutch perfectly aligned and moly grease on the points of contact, it all slides together with the gentlest of touches ... ďlike buttahĒ

This morning I took the SC to return the valve spring compressor to Steve, one of my pro mechanic and dealership veteran friends. Bright blue skies and peak fall colors; weíll be complaining about the winter soon but New England is a great place to live.

John
Old 10-15-2020, 11:12 AM
  Pelican Parts Catalog | Tech Articles | Promos & Specials    Reply With Quote #402 (permalink)
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Of false economies and extra parts orders...

When I removed the original engine, I did so by dropping it with the cross-member and steering rack. This means that I also removed the suspension control arms and sway bar.

The right control arm was clearly bent, but the left one looked good and even retained its 2/87 date stamp. Viva originality ... and frugality ... so even though a new Lemfoerder arm is just $20, I only ordered one, which I built up with new bushings and a URO ball-joint yesterday. So far so good.


This morning I came to regret that fiscal austerity.

First, I removed the sway bar bushing: cut one side off with a hacksaw and pushed out the remainder, then the front bushing, using threaded rod, large washers and big socket ... some considerable force required to move that one.

Then, I went to remove the big/rear bushing, and this was when started to wish I'd bought TWO new control arms; the bushing was a swine to remove and once I'd finally hacked it off, I found that someone had been in there before me and ruined the arm:


To avoid having to press a new rear bushing on (as I will need to do), the previous guy had ground off a serious amount of the arm's pivot/shaft end, such that my new bushing wobbled loosely on it ... it's meant to be firmly located and under tension, IIRC.

Out came the phone to find a replacement ... surely easy since these are actually VW parts? No: the VW's they fit are likely now rarer than 4 cylinder Porsches, so it's not exactly a fast mover. The big mail order house in southern Connecticut had stock ... cool, a 1.25 ride each way would be worth it. Nope ... they are still not allowing in-person will-call pickups, and can't say I blame them. So a new arm is coming from them, next week. And ... here's hoping I can uninstall those two bushings from the bad arm ... I didn't even think of that when I ordered the arm.

I can certainly get busy with the engine/crossmember in the meantime. But the lesson for others here is: how much is your time worth vs. $20? Date stamps be damned!.

John
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82 911SC coupe, 3 seasons near-daily use; 87 924S, project ... see my thread http://forums.pelicanparts.com/porsche-924-944-968-technical-forum/1046846-johnjs-87-924s-rehabilitation.html Past: 6x Alfas; 01 V70 2.4T; 95 Accord CD555; 89 944S2; 89 FJ62 Landcruiser; 82 Celica; 77 CJ5; 74 Beetle; 67 TR4A; 62 Midget; ?Year Lambretta Li 150 (my brother's actually); 76 Fiat 126 (Mum's); ?Year Isetta 300 (Dad's)
Old 10-16-2020, 08:55 AM
  Pelican Parts Catalog | Tech Articles | Promos & Specials    Reply With Quote #403 (permalink)
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Hey John,
I performed this job a few years ago and ended up just replacing everything from the arms to all the bushings, as well as the ball joints. I figured that the old 30+ yr rubber material had enough; some of it looked ok but there were small cracks and dimensions were a little skewed when mic'd...
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Old 10-17-2020, 06:57 AM
  Pelican Parts Catalog | Tech Articles | Promos & Specials    Reply With Quote #404 (permalink)
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Quote:
Originally Posted by jjeffries View Post



... and 196,000 isn't a particularly important number, but it's fun to see the odometer doing its thing. I need to send this gauge away for repair, because not only is the trip meter broken, but the speedometer is in urgent need of recalibrating; it shows a real 80 as being 60mph. I've figured out what RPM's in 5th equate to certain speeds (23.2mph/1000PRM). But it's best to keep everything working properly, so I'll try to remember to ship it to Palo Alto Speedometer once the car is tucked away for the road-salt season.

John
Hi John, Good idea to fix the speedometer this winter. Maybe we'll get no snow in Connecticut and your 911 will be a 4 season car?

My speedo is off too in the 944, but it reads 8mph higher than actual - so opposite of what you're seeing on your 911. The odometer doesn't work either. I know the gear on the odometer is a pretty easy fix, but have no idea how to fix the speedometer so I'm thinking of sending the gauge away also.
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Old 10-17-2020, 04:55 PM
  Pelican Parts Catalog | Tech Articles | Promos & Specials    Reply With Quote #405 (permalink)
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Greetings All ... I've been beavering away on this project. I started the engine installation last week, something of a dance between the engine/crossmember and the rest of the car as the engine has to be threaded on its vertical journey, front to back and front again, to clear obstacles on the way.


This is a job where one would be much better off with a two-post lift than a scissor version like mine; maneuvering the engine, on my HF 1000lb lift table, within the available space provided by both the car and lift itself, was tricky.


If I had to do this again - and I sure hope I won't - I'd spend more time leveling the engine/crossmember assembly on the lift table as I was placing it there with the engine crane; I had it too nose-down and had to do some levering and blocking with those little bits of 2X4's we all keep at hand to get it properly aimed at the driveshaft splines.


I nudged the crankshaft forwards in small increments in order to enable the clutch disk and driveshaft splines to make their acquaintances.


Yes, this would likely have been easier with a second pair of hands, but I needed to get it done solo. With some grunting and choice epithets hurled in the engine's general direction, eventually it was in.


So now I'm in the mode of methodically getting everything hooked back up. Today I used my time/backache-budget getting the A/C compressor fastened to its bracket; what a PITA. I probably should have grabbed the 2" air grinder and taken a hair of the bracket's attachment lugs to make the fit one with no interference... I see no reason for it to be quite so tight.


With the engine back in, I was looking forward to using those new control arms and getting the car back on its wheels. But you wouldn't want to put the arms back on without the sway bar that links them. I went to my stash of new parts but quickly found that what I had on hand - as specified by PET, 477 411 053G - would not work. Why? The inner diameter - where the bushing fits around the bar - was fine, but the outer diameter, where each bushing sits within its bracket, was too small (35mm OD vs the required 40mm). So what do the original parts look like, and do they have a P/N on them? A. They have the correct dimensions, and B. 951 343 794 00. These, however, aren't readily available, at least from what I can tell.

As described in the thread I found (and bumped), this is a known issue for the 924S and certain 944's with the 20mm front bar. The 944-specialist shop in FLA is the only vendor I've found who acknowledges the (numerous) different sized front sway bar bushings available; I'll follow-up with them tomorrow.

You may be wondering, why not just re-use the original 951 343 794 00 bushings? I would, but while they have the same p/n molded into them, they are two difference sizes Huh? Yes, one is approx. 10% larger, the result, I submit, of having swollen from ATF/Dexron leaking out of the Power Steering system onto the sway bar fixings.


The 924S is a funny old thing in terms of the odd collection of parts from which it was built, some things new, others old, some borrowed ...

As I wait to obtain the correct parts, I'll continue the reconnecting and plumbing. Believe me, I'm wondering if the engine will fire and run right out of the gate, or will it fight me?

John
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82 911SC coupe, 3 seasons near-daily use; 87 924S, project ... see my thread http://forums.pelicanparts.com/porsche-924-944-968-technical-forum/1046846-johnjs-87-924s-rehabilitation.html Past: 6x Alfas; 01 V70 2.4T; 95 Accord CD555; 89 944S2; 89 FJ62 Landcruiser; 82 Celica; 77 CJ5; 74 Beetle; 67 TR4A; 62 Midget; ?Year Lambretta Li 150 (my brother's actually); 76 Fiat 126 (Mum's); ?Year Isetta 300 (Dad's)
Old 10-25-2020, 02:10 PM
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John,
Please have the video cam running when you get to that point!
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Old 10-25-2020, 06:19 PM
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Quote:
Yes, this would likely have been easier with a second pair of hands
someone posted on my thread they thought this was impossible without help.

good job.
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84 928S, Ruby Red linen/brown interior - preferred DD
87 924S resurrect and gut and another track car...
86 944 turbo my new DE/track car.
78 930 clone project car.
Old 10-26-2020, 07:12 AM
  Pelican Parts Catalog | Tech Articles | Promos & Specials    Reply With Quote #408 (permalink)
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Originally Posted by 911tracker85 View Post
someone posted on my thread they thought this was impossible without help.

good job.
Bob,

Thatís kind of you but I imagine guys who do this for a living get them done by themselves with relative ease. If you had the car on a proper two post lift and the engine assembly on a good table, ideally about 3í tall, it wouldnít be a big deal.

I need to check the Engine Conversions forum to see how your LS > 911/930 is coming along.

Best, John
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82 911SC coupe, 3 seasons near-daily use; 87 924S, project ... see my thread http://forums.pelicanparts.com/porsche-924-944-968-technical-forum/1046846-johnjs-87-924s-rehabilitation.html Past: 6x Alfas; 01 V70 2.4T; 95 Accord CD555; 89 944S2; 89 FJ62 Landcruiser; 82 Celica; 77 CJ5; 74 Beetle; 67 TR4A; 62 Midget; ?Year Lambretta Li 150 (my brother's actually); 76 Fiat 126 (Mum's); ?Year Isetta 300 (Dad's)
Old 10-27-2020, 09:15 AM
  Pelican Parts Catalog | Tech Articles | Promos & Specials    Reply With Quote #409 (permalink)
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in my case I had the front of the 951 way up in the air. trans jack, hoist, and engine support beam. then tweak each until I got it bolted up.

no progress on the 911/LS, still sucking hind teet....

had to replace the alt on the 928 I sold so the guy can pick it up. and driving the 951 to finish breaking in the motor.

but today I may get the 66 mustang moved in for Jerry to get to work and I will start back to work on the 911.
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84 928S, Ruby Red linen/brown interior - preferred DD
87 924S resurrect and gut and another track car...
86 944 turbo my new DE/track car.
78 930 clone project car.
Old 10-28-2020, 06:19 AM
  Pelican Parts Catalog | Tech Articles | Promos & Specials    Reply With Quote #410 (permalink)
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Hello All,

Since my last update Iíve ordered some new parts for my front sway bar so I can get the lower elements of the front suspension back into the car. Itíll also need struts and rear shocks but I want to get it running & driving before that order is submitted. Iíve also put out a request to my Boston-area 944 used parts guru for a rear sway bar. On my Alfa GTV - a car with a fair amount of push/understeer dialed in at the factory, Iíd made a fairly common move to new F&R springs (lower, thicker), kept the stock front sway bar and chosen a fatter rear bar (5/8Ē vs stock 1/2Ē); this made for a balance I always enjoyed wherein you could play with your chosen line via your right foot as well as via the steering wheel. I look forward to making this car feel that dialed in. For struts and shocks, Iíll likely go with Boge ... but, Iím getting ahead of myself.

Today I snuck-in a few connections related to getting the engine hooked-up. Steady-as-she-goes: I donít want to make any (many?) stupid mistakes ... haste makes waste, etc., but I do need to get that center garage bay cleared out for my lovely and patient wife to bring her CRV in for the snow season.


More updates over the weekend,
Thanks for stopping by ... weíre now over 20K views.
John
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82 911SC coupe, 3 seasons near-daily use; 87 924S, project ... see my thread http://forums.pelicanparts.com/porsche-924-944-968-technical-forum/1046846-johnjs-87-924s-rehabilitation.html Past: 6x Alfas; 01 V70 2.4T; 95 Accord CD555; 89 944S2; 89 FJ62 Landcruiser; 82 Celica; 77 CJ5; 74 Beetle; 67 TR4A; 62 Midget; ?Year Lambretta Li 150 (my brother's actually); 76 Fiat 126 (Mum's); ?Year Isetta 300 (Dad's)

Last edited by jjeffries; 11-01-2020 at 07:02 AM..
Old 10-29-2020, 08:15 PM
  Pelican Parts Catalog | Tech Articles | Promos & Specials    Reply With Quote #411 (permalink)
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I'm not much of an NFL fan anymore, but to borrow one of their hackneyed cliches, why do the last five yards on a project like this always take so long, and involve the most individual orders from suppliers, and therefore the most USPS, UPS and FedEx charges? Because stuff like this happens:

I had the clutch slave back in ...


... then the starter - which I'd disassembled to clean and grease early in the project - threw a red flag just before the end-zone (more gratuitous TV-talk):


Trust me, I was not leaning on this with monster torque, but whatever force I was applying was half of a newton-meter too far for this fragile Bakelite/plastic.

BTW, this resonates with one of fundamental theories of a chapter in the book I might write, "What Makes a Proper Mechanic?" Chapter Three: "The Application of Force", subtitled, "Things You Cannot Learn Without Real Experience". In case you're wondering, by "Proper Mechanic", I'm referring to real-deal guys (and some girls) who live the technician life daily; I'd be categorized as an amateur, a hanger-on, but from the many excellent techs I've worked with over the years, I have learned much.

Plenty else to attend to in the meantime.

Best, John
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82 911SC coupe, 3 seasons near-daily use; 87 924S, project ... see my thread http://forums.pelicanparts.com/porsche-924-944-968-technical-forum/1046846-johnjs-87-924s-rehabilitation.html Past: 6x Alfas; 01 V70 2.4T; 95 Accord CD555; 89 944S2; 89 FJ62 Landcruiser; 82 Celica; 77 CJ5; 74 Beetle; 67 TR4A; 62 Midget; ?Year Lambretta Li 150 (my brother's actually); 76 Fiat 126 (Mum's); ?Year Isetta 300 (Dad's)
Old 11-01-2020, 07:18 AM
  Pelican Parts Catalog | Tech Articles | Promos & Specials    Reply With Quote #412 (permalink)
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Happy Monday Evening Friends,

I called the excellent old-skool shop I use, Al's Auto Electric in Canton, Conn and learned they had a new, albeit aftermarket solenoid on hand for a very reasonable $32, so I hopped in my daily to go grab it.

The old one, NLA, as far as I can tell:

The replacement, which BTW is now installed:


Then in today's mail, a package from the specialist supplier in FLA. Bottom line, I already had the bushings called for in PET, for the 20mm front bar, but my car had either come with, or been retrofitted to larger OD diameter holders and bushings.

Old vs. New:

What'll be going back into the car, some useful P/N's in case you ever have to do this same job on a car with a 20mm front bar; note that they included excellent quality nuts and bolts:



After a cold snap here - we had a very real 5" of snow on Friday - things are meant to get warmer tomorrow, so maybe I can sneak in some good work during my lunch break. The warm weather should make my manipulation and routing of the engine wiring harness easier (or, less difficult?)**, and hopefully I can get the front control arms and sway bar on, and look at the car sitting on four wheels again ... this time, 7" and 8" D90's with some rather butch Michelin snows.

** I commented on the following on my new thread about annoying/frustrating aspects of the 924/44/68 family:
- When I pulled my car's engine, I followed the directions from Clark's Garage, which included disconnecting the main wiring harness from the ECU and a couple of other connectors under the dash, and pulling it thru the firewall to be removed with the engine assembly.
- While I "dressed" the engine prior to installation, I did my best to get the harness in place on the engine, but I didn't get it right and am now working to get it in the right location (basically, lift it somewhat higher).
- V2Rocket944 commented that it's much smarter to NOT pull the harness with the car, but rather to disconnect it from all its attachment points to the engine. I simply didn't know, or think of that, so here I am. I'll get there, but I already have some cuts and nicks for my effort.
- Hopefully the better I get as a mechanic-in-perpetual-training, the more I can see solutions in front of me and the less I'll need to follow directions.
- (Yes, the Factory WSM is the best.)

Ciao,
John
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82 911SC coupe, 3 seasons near-daily use; 87 924S, project ... see my thread http://forums.pelicanparts.com/porsche-924-944-968-technical-forum/1046846-johnjs-87-924s-rehabilitation.html Past: 6x Alfas; 01 V70 2.4T; 95 Accord CD555; 89 944S2; 89 FJ62 Landcruiser; 82 Celica; 77 CJ5; 74 Beetle; 67 TR4A; 62 Midget; ?Year Lambretta Li 150 (my brother's actually); 76 Fiat 126 (Mum's); ?Year Isetta 300 (Dad's)
Old 11-02-2020, 05:01 PM
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Inspiring stuff, thanks for bringing us along for the ride. Just met a bloke, named Jacob with a 944S in MINT condition, given it has 160,000 mi on it (!) I think it was also an '87, perhaps your path's will cross sometime.
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Old 11-09-2020, 09:22 PM
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Getting really close now, John! The end-zone is nigh.

Quote:
Originally Posted by jjeffries View Post
- V2Rocket944 commented that it's much smarter to NOT pull the harness with the car, but rather to disconnect it from all its attachment points to the engine. I simply didn't know, or think of that, so here I am. I'll get there, but I already have some cuts and nicks for my effort.
- Hopefully the better I get as a mechanic-in-perpetual-training, the more I can see solutions in front of me and the less I'll need to follow directions.
This sounds like a character-building experience to me. Next time you'll take the easier route with swagger, because you've got the long road under your belt!

As a tennis coach (my pre-Covid gig), I instruct beginners and intermediates with strict rules and boundaries, only to later modify or throw them out the window altogether, when they're ready for the next progression. I see wrenching as similar. Once you know the rules, and have followed them, you've earned the right to bend or side-step when appropriate.

It's much harder to see those shortcuts if you haven't "wasted" time doing it the long way (or the wrong way!). All part of our training, and never really wasted effort.
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Old 11-10-2020, 04:24 AM
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JT, using Kraftwerk as your handle here is inspired. RIP Florian ... not all of the best music comes from Anglo-speaking countries. In a more recent context, I’d point to Air, from France. Obviously there are thousands of other examples that I don’t know about (yet).

Like our SC’s, these water-cooled cars (924/44/68) were built to a standard such that they will last indefinitely IF maintained properly. The bodyshells were built of excellent steel with top-quality coatings to protect them, and the mechanicals are generally stout and rebuildable. It’s when they’re allowed to go to seed that they become less viable, but even then, it’s generally not due to rust or major component failure.

Thanks for visiting this thread. In pre-Covid times, my work often took me to the Boroughs.

John
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82 911SC coupe, 3 seasons near-daily use; 87 924S, project ... see my thread http://forums.pelicanparts.com/porsche-924-944-968-technical-forum/1046846-johnjs-87-924s-rehabilitation.html Past: 6x Alfas; 01 V70 2.4T; 95 Accord CD555; 89 944S2; 89 FJ62 Landcruiser; 82 Celica; 77 CJ5; 74 Beetle; 67 TR4A; 62 Midget; ?Year Lambretta Li 150 (my brother's actually); 76 Fiat 126 (Mum's); ?Year Isetta 300 (Dad's)
Old 11-10-2020, 04:42 AM
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I'm avoiding any self-imposed deadlines to get this thing fired-up; after all, this stage of the project, with the reassembly of cleaned or new parts, is rather appealing. So, steady-as-she-goes, and quality-uber-alles are my guiding principles.

These URO coolant hoses are nice, BTW. All fit well and have a good feel to them; the only P/N they didn't have when I placed my order was the one I call Big Gulp ... from the water pump to the lower right radiator. I hadn't realized that the 924S seems to have it's own version of this, (944-106-237-06) ... there are at least two other versions for different members of the 944 family. Pelican supplies a Gates hose, 21590, for the 924S, which I obtained last week and fits nicely.




And this was in my URO stash of parts; I need to get a couple of new male T-fittings and some fresh hose ... the Cohline fitment is on B/O right now but something from NAPA will do.


Here's a beauty shot, but will be the first "What's Wrong With This?" quiz question of the day. Answer: I installed the arms with sway bar together - some geometrical tricks required, learned when I'd refreshed my SC's front end - only to realize I'd left off the $@&%! sway bar bushes. I resolved that without a complete disassembly but had to call in my 25 year old son for his superior upper-body strength to get it back together.


As noted previously, new arms are $20 from Lemsforder, made in Poland: don't eff around with the old ones unless they're still perfect.


BTW, I like the steel arms over the aluminum versions, not just for the replaceable and inexpensive ball-joints, but also their ability to deform under impact. I understand the folks who do 944 Spec Racing share the same opinion, and the alu versions aren't meaningfully less heavy anyhow.


Second quiz photo: what's wrong here? Yes, the fuel "jumper" hose is misrouted. It will be resolved before I try firing this up.


As the car stands today, on the wooden boxes (with threaded feet) I made for my SC home alignment. The reason for this is to install the exhaust without the mid-rise left being in the way. In this view the rear shocks are still disconnected from the rear control arms, from when I dropped the rear suspension, to get out the gas tank, transaxle and torque-tube ... The threads of the 14 x 1.5 x 85mm bolts that retain the lower shock eyes felt nasty going into the (aluminum) trailing arms, so I have a tap on order (and new bolts, just in case).


Will connecting the shocks pull down that rear ride height? What about adding some gasoline? I imagine that I will need to re-index the rear bars to get what I want. It still needs front strut inserts and rear shocks anyhow.

My favorite 924 (actually, a 931) is this one. Perfect ride height, or dare I say it, "stance"? Also reinforces my belief that Guards Red is NOT a great 924 color.





Best wishes to all,
John
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82 911SC coupe, 3 seasons near-daily use; 87 924S, project ... see my thread http://forums.pelicanparts.com/porsche-924-944-968-technical-forum/1046846-johnjs-87-924s-rehabilitation.html Past: 6x Alfas; 01 V70 2.4T; 95 Accord CD555; 89 944S2; 89 FJ62 Landcruiser; 82 Celica; 77 CJ5; 74 Beetle; 67 TR4A; 62 Midget; ?Year Lambretta Li 150 (my brother's actually); 76 Fiat 126 (Mum's); ?Year Isetta 300 (Dad's)
Old 11-17-2020, 07:57 AM
  Pelican Parts Catalog | Tech Articles | Promos & Specials    Reply With Quote #417 (permalink)
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John, I'm really enjoying how the car is coming together and it's great to see how clean things are before reassembly.

Sign me up for two tone 924's. I had a friend that had a two tone Turbo in blue and silver (as pictured above) and it was a good looking version.

Also, check out the 17,000 mile '88 924S that popped up on BaT (if you haven't already). Another good reference point as to how these cars looked when new.

Best to all,

Jay
Old 11-17-2020, 10:27 AM
  Pelican Parts Catalog | Tech Articles | Promos & Specials    Reply With Quote #418 (permalink)
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I was wondering if that was navy or grey below the belt on the turbo. That is a great look. Not sure I need the pinstripe however - was that a factory look also?
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Old 11-17-2020, 10:30 AM
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I believe that is navy below the belt line on the Turbo. I've seen later model non Turbo 924's with similar paint schemes. I could be wrong, but I think the pinstripe is factory...

Old 11-17-2020, 10:41 AM
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