![]() |
|
|
|
Frankly my dear....
|
![]()
I have been asked by a few forum members to ‘chronicle’ all the work that I have carried out on my 1988 944S during its long restoration. Some of the photos have already appeared in other posts at some time. However, it seems that one complete ‘start to finish’ thread was what the guys wanted.
So, rising to the challenge (it has taken a bit of time!), here is the complete story of E138WCL’s journey from the salvage yard to a head-turning classic. It will take a while to load everything, so feel free to comment as the various stages appear. Here we go..... ![]() As you can see from the photos, she is looking a bit sad ![]() ![]() ![]() ![]() ![]() ![]() ![]() ![]() Once delivered to me I stripped off the damaged wing (fender) and front panels and welded a replacement inner panel in place. Removed three – yes, three old alarm systems and repaired the electrics. Drained the fuel tank, inspected as much as I could and fired her up. Nice..... I then fitted some replacement panels, including a fibreglass S2 style front complete with original S2 lights, etc. Then I had to drill out the locking wheel nuts (no key!)..this took an age and three hole saw blades. Once the wheels were off, I replaced the discs and pads and generally serviced the calipers. Decided that as I didn’t know the service history and when the belts were last done (they looked fine..) I ordered all the necessary parts. A bunch of other minor works was also carried out on a number of systems to bring them ‘back to life’. Then took the car for an inspection to put her back on the road, it actually passed! So, I was able to take her out and about…which I did (well who wouldn’t?). However, I wish I hadn’t as I had only done about 1500 miles when the cambelt stripped teeth (rubber had perished) and the engine was toast… ![]() At this point, the car sat on my driveway for some time (quite a time actually!) while I decided what to do next.
__________________
Porsche - accept no substitute Blue 1999 Boxster - Brief encounter! Black 1988 944S - Ongoing project Black 1987 944S - Gone but not forgotten Metallic Black 1980 924 - Those were the days.... Red 1979 924 - Hmm Minerva blue 1979 924 - Where it all began! |
||
![]() |
|
Frankly my dear....
|
It's dead Jim....
Finally got around to assessing the damage, knowing pretty much what I would find. Stripped the engine and removed the head, 8 bent valves, basically all the inlet ones. Priced up replacement valves and all the other work and parts involved and decided to get myself a complete working replacement engine. This ‘new’ one would be then rebuilt as much as possible , cleaned and fitted - so the hunt began for a suitable donor car.
Found a lower mileage S (87K) that was really shabby, lots of rust and only suitable for parts: ![]() ![]() ![]() ![]() Got it home and removed the engine, as below: ![]() ![]() ![]() ![]() ![]() ![]() Stripped it down and replaced the following: Cambelt and balance belts ALL belt rollers and tensioner rollers Head gasket ALL cylinder head camshaft box seals Balance shaft oil seals Camshaft chain Camshaft chain tensioner pad Rear main crankshaft seal Other engine gaskets and o rings - as necessary Exhaust manifold gaskets Thermostat Engine mounts Oil cooler seals and gasket Complete set of Beru spark plug (EHT) leads Spark plugs (copper) Distributor rotor arm and cap While doing that, I extensively cleaned the engine, repainted components and inspected things like the water pump (it appeared to be a replacement with no leaks and a good bearing). I had noted the oil pressure on the long drive back from the PO and it was good, so decided not to do the rod bearings. Then replaced the following clutch components: Clutch pressure plate Clutch plate (friction) Clutch thrust (release/throw out) bearing Pilot (spigot) bearing
__________________
Porsche - accept no substitute Blue 1999 Boxster - Brief encounter! Black 1988 944S - Ongoing project Black 1987 944S - Gone but not forgotten Metallic Black 1980 924 - Those were the days.... Red 1979 924 - Hmm Minerva blue 1979 924 - Where it all began! |
||
![]() |
|
Frankly my dear....
|
![]()
The engine was, at this point looking good:
![]() ![]() ![]() ![]() So (while I was in there) I decided to clean the engine bay and replace the clutch master and slave cylinders along with the flexible hose…. ![]() ![]() ![]() ![]() ![]()
__________________
Porsche - accept no substitute Blue 1999 Boxster - Brief encounter! Black 1988 944S - Ongoing project Black 1987 944S - Gone but not forgotten Metallic Black 1980 924 - Those were the days.... Red 1979 924 - Hmm Minerva blue 1979 924 - Where it all began! |
||
![]() |
|
Frankly my dear....
|
![]()
Then fitted the rebuilt motor:
![]() ![]() ![]() ![]() ![]() Fitted all stainless steel pipe clamps Repaired the PS pump with a gasket kit - as these things like to leak! Replaced the external belts (PS and Alternator) Did an oil flush, new filter and oil change Did a coolant flush and filled with new coolant Replaced the air filter Fitted a new battery After a few ‘false starts’ and a bit more minor work, she fired up..again...nice ![]()
__________________
Porsche - accept no substitute Blue 1999 Boxster - Brief encounter! Black 1988 944S - Ongoing project Black 1987 944S - Gone but not forgotten Metallic Black 1980 924 - Those were the days.... Red 1979 924 - Hmm Minerva blue 1979 924 - Where it all began! |
||
![]() |
|
Frankly my dear....
|
![]()
Then decided that I would overhaul the front suspension components, cleaning, repainting and refurbishing as much as possible. Also replaced:
Front struts Front wheel bearings Front flexible brake pipes with stainless steel braided ones Brake dust guards Both front tyres Bonnet (hood) struts Front caliper seals, pad retaining springs and pins Caliper bleed nipples with stainless steel ones Headlamp relay rubber cover Air filter box to AFM rubber seal At this point I noticed that the sills (rocker panels) had developed a ‘bit of a rash’. They had actually rusted out quite badly. See what I found: ![]() ![]() ![]() ![]() ![]() ![]()
__________________
Porsche - accept no substitute Blue 1999 Boxster - Brief encounter! Black 1988 944S - Ongoing project Black 1987 944S - Gone but not forgotten Metallic Black 1980 924 - Those were the days.... Red 1979 924 - Hmm Minerva blue 1979 924 - Where it all began! |
||
![]() |
|
Frankly my dear....
|
![]()
Cut out all the rot and went off to my local Porsche breaker and specialist. They had just finished stripping a really good 944 that had blown its engine. The sill panels were solid, so they cut them out for me:
![]() ![]() ![]() I then spent a lot of time cleaning the panels up to get them ready for welding, etc. I had thought it best to use original metal where I could, as the fit would be so much better. So, out with the welder (had some help here!): ![]() ![]() ![]() ![]() ![]() Real progress was being made. However, the restoration was probably into its third year at this point. ![]() ![]() Of course, the other side needed doing too!
__________________
Porsche - accept no substitute Blue 1999 Boxster - Brief encounter! Black 1988 944S - Ongoing project Black 1987 944S - Gone but not forgotten Metallic Black 1980 924 - Those were the days.... Red 1979 924 - Hmm Minerva blue 1979 924 - Where it all began! |
||
![]() |
|
![]() |
Frankly my dear....
|
![]()
While I was doing the body work, I decided to go the whole way and drop the entire rear suspension for a total refurb, as well as replace the tatty and rusted fuel hard lines. The suspension was looking like this:
![]() ![]() So it all had to come off, fuel hard lines too. I then extensively cleaned the floorpan, gas tank, wheel arches, and every little crack and crevice in the bodywork I could find. Over painted the rubber under seal with a flexible enamel paint after treating any small rusty areas first. Bought a roll of Kunifer pipe and some bending tools as well as various high-pressure fittings. Then fabricated complete new hard lines and also replaced all the rubber fuel pipes with new original Porsche parts. The fuel pump was removed and cleaned, the filter replaced, and all the pipe fixing clamps replaced. The sills were then wax injected for protection - that is a real messy job ![]()
__________________
Porsche - accept no substitute Blue 1999 Boxster - Brief encounter! Black 1988 944S - Ongoing project Black 1987 944S - Gone but not forgotten Metallic Black 1980 924 - Those were the days.... Red 1979 924 - Hmm Minerva blue 1979 924 - Where it all began! |
||
![]() |
|
Frankly my dear....
|
![]()
As it was now winter, and working on the car was impractical due to the weather, I decided to buy a DIY electroplating set and set about replating as many suspension and other fittings as I could - this was hard work, but real fun!
![]() ![]() ![]() ![]() ![]() ![]() ![]() ![]() As you can see I - refurbed the trailing arms, stripped and refurbed the rear calipers, replaced the seals, pins and springs too. The non-plated parts were cleaned, de-rusted and re-painted, the smaller suspension parts were looking fine... ![]() I had the torsion bar tube on the bench and the roll bar (anti sway) hanging from the ceiling of the garage - they were also cleaned, and extensively re-painted. The muffler heat shield was cleaned and painted with a HT paint, and when the weather was not too bad I got underneath and cleaned the transaxle assembly too. At this point I think I could see the light at the end of this particular very long tunnel...but I began to realise all this cleaning and attention to detail was becoming a bit obsessive ![]()
__________________
Porsche - accept no substitute Blue 1999 Boxster - Brief encounter! Black 1988 944S - Ongoing project Black 1987 944S - Gone but not forgotten Metallic Black 1980 924 - Those were the days.... Red 1979 924 - Hmm Minerva blue 1979 924 - Where it all began! |
||
![]() |
|
Frankly my dear....
|
![]()
Several months passed as I refurbed the suspension parts, so when the weather got warmer I started to rebuild the back end.
New rear shocks were fitted New rear shoes for the handbrake were fitted A good pair of very low mileage rear axle shafts were sourced and fitted The transaxle oil was drained and replaced (Swepco) Flexible brake pipes replaced with stainless steel ones Stainless steel exhaust system (rear muffler) fitted The results are: ![]() ![]() ![]() ![]() ![]() ![]() ![]() ![]() Putting the suspension back together with the parts in this condition was a real joy as I didn't really get my hands dirty for once!
__________________
Porsche - accept no substitute Blue 1999 Boxster - Brief encounter! Black 1988 944S - Ongoing project Black 1987 944S - Gone but not forgotten Metallic Black 1980 924 - Those were the days.... Red 1979 924 - Hmm Minerva blue 1979 924 - Where it all began! Last edited by rhett; 09-10-2013 at 12:27 PM.. |
||
![]() |
|
Frankly my dear....
|
![]()
To continue...
![]() ![]() ![]() ![]() The sills were then finished...not too shabby? (for an amateur): ![]() ![]() Things were certainly nearing completion now... ![]()
__________________
Porsche - accept no substitute Blue 1999 Boxster - Brief encounter! Black 1988 944S - Ongoing project Black 1987 944S - Gone but not forgotten Metallic Black 1980 924 - Those were the days.... Red 1979 924 - Hmm Minerva blue 1979 924 - Where it all began! |
||
![]() |
|
Frankly my dear....
|
![]()
During the project I also did the following:
Repaired the sunroof mechanism – now fully operational Fitted a remote control central locking system, with rear hatch release too Replaced the hatch pins and struts (I know…but the dreaded delamination hasn’t happened ![]() Replaced the hatch rubber seal and all three wiper blades Fitted some higher output headlamp bulbs The interior was also stripped out and practically everything replaced: Dashboard Front seats replaced with Porsche script fully electric ones Rear seats and door cards to match front seats Black carpet Momo steering wheel fitted with ‘special’ custom made horn push So it looks like this in the cabin: ![]() ![]() ![]() ![]() ![]() The silver trim may not be to everyone's taste, but I think it just brings the cabin a bit more up-to-date, so I tried not to overdo it!
__________________
Porsche - accept no substitute Blue 1999 Boxster - Brief encounter! Black 1988 944S - Ongoing project Black 1987 944S - Gone but not forgotten Metallic Black 1980 924 - Those were the days.... Red 1979 924 - Hmm Minerva blue 1979 924 - Where it all began! |
||
![]() |
|
Frankly my dear....
|
![]()
When I took the car for its inspection, it looked like this:
![]() ![]() ![]() ![]() ![]() ![]() ![]() She passed the inspection with a glowing report from the tester, he was knocked out by the condition of everything. One thing was needed for the pass, an adjustment of the mixture and a good rev at nearly the limit to clean out the cylinders, etc. The emissions were then very low and a certificate issued..she was legal again! ![]()
__________________
Porsche - accept no substitute Blue 1999 Boxster - Brief encounter! Black 1988 944S - Ongoing project Black 1987 944S - Gone but not forgotten Metallic Black 1980 924 - Those were the days.... Red 1979 924 - Hmm Minerva blue 1979 924 - Where it all began! |
||
![]() |
|
![]() |
Frankly my dear....
|
![]()
So, she is back on the road again and here are the most recent shots. I made some carbon-fibre effect vinyl stone guards too:
![]() ![]() ![]() ![]() ![]() ![]() ![]() Looking just a bit better than when I first got her...
__________________
Porsche - accept no substitute Blue 1999 Boxster - Brief encounter! Black 1988 944S - Ongoing project Black 1987 944S - Gone but not forgotten Metallic Black 1980 924 - Those were the days.... Red 1979 924 - Hmm Minerva blue 1979 924 - Where it all began! |
||
![]() |
|
Frankly my dear....
|
![]()
Recently fitted a new radiator header tank to tidy the engine bay further:
![]() ![]() Was it worth all that work??? Yes, I think so…However, I dread to think what it has cost in parts but a conservative estimate must be around £4000. That is the story so far. However, there is actually still quite a bit that I need to get around to do, but for the meantime I can actually drive her and that (in my opinion) is what it is all about really! Hope you enjoyed the thread. ![]()
__________________
Porsche - accept no substitute Blue 1999 Boxster - Brief encounter! Black 1988 944S - Ongoing project Black 1987 944S - Gone but not forgotten Metallic Black 1980 924 - Those were the days.... Red 1979 924 - Hmm Minerva blue 1979 924 - Where it all began! |
||
![]() |
|
Andrew Gawers' Dad
Join Date: Apr 2011
Location: Andrews moms house, CO
Posts: 1,898
|
Wow, looking good, thanks for sharing!
|
||
![]() |
|
Registered
|
Nice work!
__________________
BMW 328i 6-speed Tacoma 4wd Cessna 172 |
||
![]() |
|
Registered User
|
Wow! Great restoration! But did the euro versions not have the side markers on the front bumper?
|
||
![]() |
|
Registered User
Join Date: Apr 2004
Location: Louisville Ky
Posts: 2,791
|
Wow ! Thank you for sharing. Your journal & photographs would make for an excellent book.
__________________
Edgar 1984 Porsche 944 bone stock 1995 Mercedes E320 wagon 1970 Honda CB350 mint!!! |
||
![]() |
|
Registered User
Join Date: May 2012
Posts: 383
|
Fantastic work, mate. Fantastic.
__________________
'78 924 "NA" '87 944 "S" '93 968 "SC" |
||
![]() |
|
Registered
Join Date: Dec 2011
Location: Space-time continuum
Posts: 1,188
|
Quote:
Awesome job. You must be super proud of yourself! Always nice to work on them clean. ![]() But - you put the interior together backwards!!!!! Take care, Last edited by FrenchToast; 09-10-2013 at 03:58 PM.. |
||
![]() |
|
![]() |
Thread Tools | |
Rate This Thread | |
|