Update on my 928

[Awaino]

Well, as I'm sure many have done before me, I opened a can of worms. What started out as a basic front end rubber refresh and new fuel hoses, has gone quite out of control. I found more more problems while I was taking various things apart. This is where I am at now.
1. The fuel system. Waiting for a few crush rings to get the fuel pump and filter back together. The main rubber portions of the fuel line have been replaced. The injectors are back from WitchHunter with much better numbers than when they started. The fuel rails and injector clamps have been cleaned up and powder coated(yes, the hose connections will be cleaned up prior to putting the new hoses on). They look amazing. This leads me to the next problem. They look so good next to the plenum and distribution tubes that I am thinking of taking that apart and powder coating as well. This gives me 3 things. 1, much better looking plenum and tubes, 2, access to the top of the engine so that I can get all the sludge off, and 3, acces to the throttle body and replacement of the seals and various parts that are all 31+ years old. Any thoughts on this? Some before and after pics as of tonight.




















Problem 2. Front end rubber refresh. This has so far ended up in 2 front upper control arms due to bad ball joints, a leaking rack (reservoir, hoses, bushings, boots, rack), and now bad shocks as well. Waiting for shocks and a few misc steering parts to show up to put all of that back together. New tires, and wheels while I was at it as well. It seems as though the tie rods and lower ball joints are ok at this point.

Problem 3. Plastic cover on alternator broken, hose completely missing. Parts are incoming for this fix. I'm wondering if this is part of my no cold A/C problem.

[Awaino]

Problem 4. Missing front grill, spoiler, inner fender plastic, and damaged passenger front fender. I have no plan as of yet for how to fix this.



Problem 5. Severely rusted battery box. No plan as of yet.



Problem 6. Rust bubbles under the paint. No clue where to start.



Problem 7. Transmission fluid leak. Not sure where from yet.



And that's my crazy project list right now. There are more problems I'll get to, but this is it for now.

[Awaino]

A few other pics.


Rack leak.



Good side.



There is a new o-ring here now as well.



These were fun to get in.

[The Deputy]

If that bubbled up section of paint is on the same fender/wing as the cracked portion where the chin spoiler mounts...I'd just try to find a new one. It looks as though there is some sort of body filler in that bubbled area and below. The cracks from where the chin spoiler came off could be repaired...but sourcing another one would make more sense, in my opinion. If you aren't in a big hurry, 928 International usually has a half-off sale on their used parts between Thanksgiving and New years (I believe it's between those two dates) or ebay has fenders on there all the time.

And yep...you have to be careful dressing up one part without going hog wild under that hood. Something nice and shiny sure makes the rest look out of place or vise versa. I just finished doing everything under the hood that you are tackling and the thought crossed my mind too spruce things up under there...but then I decided to just go for a more factory look. Kind of glad I did, since other projects were in the works and I didn't want to become overwhelmed with them...before I even had a chance to drive the beast.

Maybe when the engine comes out eventually I'll get things dressed up. I imagine head gaskets are in my near future...so it makes more sense to do it then.

With what you have done so far...by powdercoating the fuel rails...I'd probably polish the plenum and intake tubes and replace the black connecting hoses with blue ones, helping to tie your blue theme together. However, before you go much further on that top-end...I'd get a shopvac in there and suck up as much of that crud as possible and blow the rest out with compressed air. Tape off those open ports first for your injectors and mass air flow of course.

Good luck and keep us up to date on your progress. Looks like quite the project and looks very similar to what I just did on my 84.

Brian.

[The Deputy]

Another thing...you are going to do the motor mount...right?...since you have the majority of the front end apart already. Plus, if your rack is leaking...you may just want to drop it out and reseal it on the bench. Much easier that way and adds too the chances of successfulness, working underneath the car always adds an element of difficulty. Mine need replaced, but I held off. Since like I mentioned, the engine may be coming out someday soon, but if the engine doesn't show signs of head gaskets leaking by fall...they will get done this winter from the bottom side. And boy can you feel a vibration when accelerating, not bad if you really put your foot in it, but if you accelerate what my wife calls...normally...it's rather annoying.

Side note...all of your pain and suffering will be worth the battle. The car is absolute awesome. I've logged a little under 400 miles in the past week or so...and it just keeps getting better and better as she grows on me. While entering the expressway last night after dining out...I showed my wife the difference between the Silverado and the 928 on the 25 mph cloverleaf ramp leading to the expressway...let's just put it this way...if it weren't for her seatbelt, she'd have been in my lap...lol

Brian.

[Awaino]

Fender is front passenger, rust is lower part behind Driver side door unfortunately. I have thought about the motor mounts. That's as far as it went. The rack will be swapped tomorrow. Already have a new one. It seems there are a million "while you are in there jobs". I tried a shop vac on the crud and it's not budging. I'm going to have to scrape it. Do you know where to get blue connector hoses? The plan is to do all the vacuum hoses and plug wires blue as well. The heads will be off at some point and will be blue with black Porsche lettering. The logo on the plenum will be painted like an actual badge with high temp clearcoat to protect it. That's the vision in my head anyway. I'm at a crossroads. Put it together as is and participate in our local PCA auto cross on 5/16, or basically plan on not driving it this summer at all. My OCD is gong nuts to make it right, while my need to drive my baby is also pegging. Thanks for the positive words. My wife just shakes her head when I press the go fast button, lol.

[Awaino]

Not too much done on BluTwo this weekend. I did get the rails put back together today. Test fit turned out pretty well, and I'm pleased with how the powder coat looks. It makes the other stuff look,like crap, but oh well...

[5l32v4c]

Remember that song from the eighties by The Fixx called "One Things Leads to Another"? - 928 theme tune.

Liking the new parts BTW.

[davetr]

how hard was th rack to get out ?? mine is leaking I need to reseal it

[AirtekHVAC]

Good work so far.....if the battery box still seems solid, clean with a baking soda / water mixture / old toothbrush. Dry thoroughly. Use rust oleum rust converter spray, then spray with cold galvanizing spray. After it dries, spray primer, spray paint, then seal with an acrylic or clear enamel...that's what I would do, anyhow...all from lowes...30$ +\-

[The Deputy]

Originally Posted by Awaino

Do you know where to get blue connector hoses?

I saw them on "MPDano" car...in the common problem topic/sticky at the top of the page, post 19.

Maybe PM him.

Brian.

[Awaino]

Got the new fuel filter and pump installed. Both rails are back in. New rubber hoses everywhere else. Almost everything is connected. Only slight marring on the powder coated nuts, which makes me happy. I was a bit worried about that. 2nd check tomorrow and then a system pressure test. Fingers crossed....

[The Deputy]

Well at least it's under the air cleaner housing (marred nut).

[DaveMcKenz]

What did you use for the short fuel hoses?
Dave

[Awaino]

I bought the whole kit from Roger an 928's R Us.

[Awaino]

Here's the update for tonight. Fuel pressure test passed. No leaks. I wasn't sure the fuel pump was running because it was so quiet! I put the air intake system back together and started her up. Runs like a champ. Can't even really see the nice looking rails under the air intake tubes. I do have a question though. On the passenger side of the air filter box (upper portion), there is a connection for a hose down below. I can't get it to even come close to connecting. Am I doing something wrong?







Also fixed the windshield washer squirter connections since I was in the area.

[The Deputy]

Originally Posted by Awaino

I do have a question though. On the passenger side of the air filter box (upper portion), there is a connection for a hose down below. I can't get it to even come close to connecting. Am I doing something wrong?

No, you're doing nothing wrong...mine doesn't line up worth a darn either.

Your picture did inspire an idea though. My air pump is making a little bit of noise, bearing wise, and seeing that open end of the hose got me to thinking about putting a mixture of auto trans fluid and penetrating oil down it. Just to see if it would suck it into the pump and maybe lube those bearings some.

Glad you got your car running, always a good feeling after any repair for sure.

Question, do you remember the size of that injector line hosing? It looks to be 7.5mm, since it looks the same diameter throughout its length. I used 7mm and it was smaller diameter, narrower, between the fitting ends, kind of like the way the origin hose looked...and l didn't use any injector hose clamps. Just wondering what size Roger is selling.

While I was under the hood, I also did all of the vaccum lines...some looked okay...but once they were bumped or rerouted to get at something else...they leaked.

Brian.

[Awaino]

Vacuum lines are on the list also. Next fall/winter though. I need to drive! Still have the front end to put back together. Waiting for front shocks.

Oh and it was 7.5 mm hose.

[Luccia at Pelican Parts]

Love the color!

[The Deputy]

Originally Posted by Awaino

I need to drive!

I get that, for sure.

Oh and it was 7.5 mm hose.

Thought so. I found 7.5 to be somewhat loose and went with the 7mm stuff myself. Ineresting.

Good luck with the rest of your repairs.

Brian.