Project Avocado - 1986 Moss Green 911 Rebuild

[chrisbalich]

Originally Posted by jpnovak

Looks like a very fun trip. Glad you were able to get away and share.

Makes me want to take a road trip.

Luft by car would be nice.
September is pretty nice in central IN...

[lateapex911]

Cool travelog!

So, slight tangent. I used to live in Newport Beach, and I've driven my 911 up to SF to visit friends a number of times. I also rode my Ninja up the PCH one day, a day that set heat records, unforgettable....buuuutttt....

So, the tangent: So Gabe, you just did what I didn't do enough of when I lived in LA. USE California. Now, I was rebooting my career...30 yrs old, getting into the automotive design and prototyping industry....it's an "art field" of sorts in that everyone thinks it's 'cool' and fun so jobs are a bit sketchy for a guy just getting started. I loved my job but the pay, and the sometimes long (100 hr weeks sometimes) sucked.

I wanted to do more "CA things" , but the normal evils of time and money conspired to put a damper on it. Then my mother, in CT, got elderly and sick and I had to move back to care for her, and got stuck..

I'm dying to move back, but it's NOT simple, nor easy.


Soooooo....

To those of you living in CA: I know it's expensive, and can be a crush of work and freeways, and it's easy to get consumed in the day to day as Gabe said....but the state is a treasure. Yosemite is a reasonable drive from LA, the coast is loaded with cool destinations, some off the beaten path, so MANY options. Do weekend trips. Take a Friday off or a Monday (or both!) and get out and enjoy the state. Be a tourist in your own backyard. It's one of my life's regrets that I didn't take advantage of what was so close.

And Gabe, thanks for chronicling the trip, WAY cool.

[jjeffries]

Jake, well said.

John

[Ryan_Cunningham]

Originally Posted by lateapex911

Soooooo....

To those of you living in CA: I know it's expensive, and can be a crush of work and freeways, and it's easy to get consumed in the day to day as Gabe said....but the state is a treasure. Yosemite is a reasonable drive from LA, the coast is loaded with cool destinations, some off the beaten path, so MANY options. Do weekend trips. Take a Friday off or a Monday (or both!) and get out and enjoy the state. Be a tourist in your own backyard. It's one of my life's regrets that I didn't take advantage of what was so close.

Great advice. We moved back to San Diego one year ago after leaving in 2018 when I left the military. We lived in Virginia for the two years between and not a day goes by where we are thankful for being able to move back.

[lateapex911]

Originally Posted by Ryan_Cunningham

Great advice. We moved back to San Diego one year ago after leaving in 2018 when I left the military. We lived in Virginia for the two years between and not a day goes by where we are thankful for being able to move back.

Cool, and thanks!
And....did you mean "...not a day goes by that we aren't thankful for being able to move back"???

Also, dare I ask how you swung it?? While the cost of living is a bit more then here in Fairfield County CT, there are pockets of affodable homes here, which I own one of. I need to REALLY do some research but the real estate pricing is daunting in CA.

Seems like moves TO CA are done young (like I did eons ago), of via work relocation or new job offer with relo package)

Seems to me there are cheaper homes but they are in REALLY sketchy places and tiny, or a loooong way from work....and tiny. LOL

I would be happy with a severe fix it upper, if it had space for, or a decent garage, and if not on the temperate coast, a pool. (busted filer is fine LOL) And a somewhat reasonable commute.

But even allowing for a complete POS, and a fairly long commute, it sure seems like there is very very little that's even remotely affordable. (Like $400=500K...which, in pretty much 80% of the country gets you a fair house, LOL)

(I'm just starting the job search)

[Gabe.]

Originally Posted by jpnovak

Looks like a very fun trip. Glad you were able to get away and share.

Makes me want to take a road trip.

Thanks Jamie, it was an awesome trip. Reading back through my posts makes me want to do it again. Thankfully I have another road trip planned back to the Midwest in August and I'm also doing the Overcrest rally in Utah with the Avocado so I'll get my fill.

Originally Posted by chrisbalich

Luft by car would be nice.
September is pretty nice in central IN...

Hopefully, Megan and I will be there!

Originally Posted by lateapex911

Cool travelog!

So, slight tangent. I used to live in Newport Beach, and I've driven my 911 up to SF to visit friends a number of times. I also rode my Ninja up the PCH one day, a day that set heat records, unforgettable....buuuutttt....

So, the tangent: So Gabe, you just did what I didn't do enough of when I lived in LA. USE California. Now, I was rebooting my career...30 yrs old, getting into the automotive design and prototyping industry....it's an "art field" of sorts in that everyone thinks it's 'cool' and fun so jobs are a bit sketchy for a guy just getting started. I loved my job but the pay, and the sometimes long (100 hr weeks sometimes) sucked.

I wanted to do more "CA things" , but the normal evils of time and money conspired to put a damper on it. Then my mother, in CT, got elderly and sick and I had to move back to care for her, and got stuck..

I'm dying to move back, but it's NOT simple, nor easy.


Soooooo....

To those of you living in CA: I know it's expensive, and can be a crush of work and freeways, and it's easy to get consumed in the day to day as Gabe said....but the state is a treasure. Yosemite is a reasonable drive from LA, the coast is loaded with cool destinations, some off the beaten path, so MANY options. Do weekend trips. Take a Friday off or a Monday (or both!) and get out and enjoy the state. Be a tourist in your own backyard. It's one of my life's regrets that I didn't take advantage of what was so close.

And Gabe, thanks for chronicling the trip, WAY cool.

Love it Jake!

The "using California" is something I've been increasingly aware of throughout the pandemic. It's too easy to stick in your bubble and with my wife having a "regular" job, even if it is currently remote, has stopped us from taking the time to explore like we really should. With a regular workweek, weekends seem like the only time to get out which makes exploring difficult because it's the same time everyone else is out. I really want to share the travel experiences with my wife but I can't let it stop me from not leaving LA when it's stressing me out.

I've lived in Los Angeles for a little over 9 years and at some point may move elsewhere but before that happens I really want to use it for the jumping-off point that it is. Still need to go to the Grand Canyon, Zion, Anza Borreaga, back to Yosemite (last time I went was in high school), up to the PNW, Idaho, Alaska, and likely so many other places I haven't yet heard of before we take that plunge.

Thank you for reminding me how lucky I am.

[lateapex911]

hey, no problem, but, you have a good handle on it I think!

[Gabe.]

Have I ever been accused of leaving well enough alone?

Since I initially painted my car I knew that I'd want to redo it at some point. The prep work and products I used left a bit to be desired...

Being that I'll probably respray the entire car I've debated on two things:

1. Partial backdate to lighten the car a bit.
2. M491 tribute to make this thing a widebody which both looks cool and offers a plethora of tire options.
3. A mix of those two.

When I ordered fiberglass panels to finish my other car I decided to order a backdate hood and rear bumper, found a front carrera RS bumper in the classifieds, and had the front fenders leftover from my other project.

A month or two later I decided maybe I should just go the widebody route instead. I had the front flares left over from my other project and picked up a set of rears.

Yea, I'm indecisive. I figured the worst that could happen is that I part ways with this stuff via the classifieds.

After getting stalled out on Vanagon progress this weekend I decided to do a test fit of the widebody panels:













Looks pretty incredible to me!

I think I've decided to weld the widebody fenders on and leave it as an impact bumper car, for now. Now to decide if I should slap the helion composites carbon fiber roof on while it's apart.

I'm also due for an oil change so I might as well take the engine out

While it's out I'd like to get the transmission rebuilt, replace the valve stem seals, any other rubber seal, valve adjustment, and maybe a set of cams?

Anyone have an opinion on a good cam option for a single throttle 964 engine that will pass smog?

[Evan Fullerton]

Elgin has/had a Super C2 cam profile. That’s what was in this 964 that went on to become “The Growler” after Alex bought it. It always passed smog with a 993 Cat and 993 exhaust manifolds.

https://youtu.be/_ixWa6FWWT4

I got a 1:32.1 out of it at Big Willow and it would do 143mph down the front straight (Rev limiter in 4th). I think it only put down 256whp or so on Hennessy’s Dynojet dyno. Had a bit of a lumpy idle but sounded good.

[dustim04]

Those fenders look pretty aggressive.

[chrisbalich]

IB widebody cars look so good.
I kinda hate you.


I have rear fender extensions for a widebody IB if you need some. Shoot me a text.

[1980 SC Targa]

Honestly shocked reading that you're going to take it apart. Then I saw the taped on fenders. Yeah take it apart lol. Looks so mean.
Engine out for oil change totally reasonable.

[Gabe.]

I have a much larger update when I can find the time to draft a post... *hint* the cutoff wheel has 100% made an appearance.

I put my black set of minilites up for sale: http://forums.pelicanparts.com/porsche-911-used-parts-sale-wanted/1103914-fs-minilite-mag-wheels-16x7-16x8-w-tires.html

Hit me up if any of you have interest

[Gabe.]

Well, this project has escalated...

Life has changed quite a bit in the last few months which is why there's been a lack of updates. I'll attempt to bring this thread up to date for you today.

I last left you at the end of July with widebody dreams. Your dreams have come true but it hasn't been without the nightmare of rust and undisclosed and unknown bodywork.

In this update, I'll show you what I discovered, what I have since fixed, and where I'm at right now (all within the 10 pics allowed per post).

While waiting on machine work for my Vanagon I decided to dive into some Avocado projects. A lot of this prep had a self-imposed deadline of the Overcrest Rally which was September 23-26. I also already had a three-week "vacation" planned in the middle of this, end of August/beginning of September.

If I had only been adding the fender flares and not bonding on a carbon roof or dealing with rust issues I think it was a totally realistic timeline. When I found a dime-sized rust hole behind the passenger side rocker cover, I got worried. You never know what something like that might turn into. In my case... it was really bad.

After I found the hole the size of a dime, I wire wheeled that area:



When I saw how bad it was, I cut that portion of the quarter panel out:



When I saw how bad it was underneath, I cut more out:



It was at this point that I really began to get worried. You can see that the entire rear portion of the outer rocker cover is nearly completely rusted away. I also noticed as I was cutting that I was cutting through body filler. In the next pic you can see that there are weld marks that have been ground down. Someone had cut a portion of the panel out and welded in a new piece. Not a problem, I'll be sectioning in a new piece too but what they did do wrong was not drilling out the spotwelds to replace the entire flange as well as incorrectly reassembling the pieces to leave a big open hole at the end of the rocker cover that they filled in with foam :facepalm:



At this point I knew I wouldn't make the rally. I ended up buying an Audi RS3 to use for the rally. I still have it, it's frickin sweet and is the nicest car I've ever owned, but I'm waffling on whether or not to keep it.

When I came back from the rally and found some more motivation, I cut the remainder of the latch panel flange off. What the prior body person did was weld their sectioned panel to that flange, that probably melted whatever undercoating or protection was there and allowed water in which rusted the sheet metal that the latch panel is welded to.



After cleaning this all up and realizing I was getting to the top of the mountain I found a bout of motivation to start making patch panels and finish welding. This is what we ended up with:



And then with a lick of epoxy primer! Once this has undercoating you'll never be able to tell there was work done, not that you can see this area anyways. That's why I never noticed it and I've really been THROUGH this car and you know it.



As for the fenders, here are a few sneak peaks. I test fit with cleco pins then cut through both panels with a cut off wheel. That gave a great gap to weld. Starting at the top of the panel it was a cut/weld/cut/weld/cut/weld process until you were down at each end and the old flare essentially popped out.







This is where the car is sitting currently. My next step is to section in the new outer rocker cover, latch panel, and quarter panel. Epoxy prime and then undercoat with Wurth SKS. Once that's done, I can move onto bonding the roof and the bodywork on the flares.

I already have some updates that are kinda car related for the next post since I'm out of room for more pictures...

[pkabush]

Nice! What an adventure. I love the newest iteration. Nobody wants a skinny avocado

[Trackrash]

Looking good. Nice job welding those flairs.

I’ve always been a fan of the IROC look. 😎

[1980 SC Targa]

Wow what an adventure. But it's looking great!

[BoxsterGT]

Gabe-
I searched for more info on your Vanagon you mention occasionally. Do you have a separate post on it?
I am very interested, since I have a couple DOKA's needing resto.
Len

[Matthew_VA]

such a great thread! thank you for keeping us updated on your adventure with the avocado--very impressive.

[Gabe.]

Thanks for following along! Half the fun is sharing the journey.

Originally Posted by BoxsterGT

Gabe-
I searched for more info on your Vanagon you mention occasionally. Do you have a separate post on it?
I am very interested, since I have a couple DOKA's needing resto.
Len

Hey Len,

I haven't started a build thread on that one yet. I started building an AHU/1Z TDI for it and stalled out when I needed to get the mk3 injection pump bracket machined for the mk4 pump. My cousin has had the parts since August and ended up getting super busy and not being able to get to the machine work since then.

It's a 1987 Vanagon Syncro tintop, non-locker.



I might as well update you all on life updates too since everything is interrelated.

After going back "home" to the midwest in August/September we really got the bug to move back there. We've been in Los Angeles for ~10 years and in the last 1.5-2 years it's really changed for us. We've had a lot of friends leave and the cost of living has gotten so extreme that it's just a constant state of frustration. There are still a lot of things to love about being here but I'm not sure it's enough to keep us. We'd rather be closer to family at this point.

I've been working from home for ~6 years and my wife has been remote since the start of the pandemic and will continue to be so for the foreseeable future. With that as our new reality we've really started to consider it.

We've settled on exploring the Twin Cities area more and after spending last week there exploring, Golden Valley seems like the place we'll land when we find a house we like.

So while our house has only a few furniture pieces we want to bring back, the garage is a PRETTY BIG issue since I have/had three disassembled projects and a total of six vehicles. As of two weeks ago we had:

• 1986 Porsche 911 - Project Avocado
• 1973 Porsche 911 - The Potato. A shell that I started turning into an RSR.
• 1974 Chevy C10
• 1987 Volkswagen Vanagon Syncro
• Audi Q5 TDI
• Audi RS3

The Avocado isn't going anywhere. I'm pretty attached to that car. It's getting the rust repaired, widebody, carbon roof, and the suspension/brakes from the Potato shell.

I sold the Potato a few weeks ago. I was initially sad about it but then when I realized how much space I got back physically and mentally, it was a really nice feeling!



I put my truck up for sale but only halfheartedly, I think I want to keep that one.



The Vanagon was purchased to build an exploration vehicle for dispersed camping. A big part of that was probably from pandemic fatigue and wanting to get out of our house. I'd probably consider selling that one either with or without the TDI swap so I don't have to move it.

The RS3 was an impulse purchase so I had something to drive for the Overcrest rally. It's a frickin sweet ride and it's nice to have something new with all the bells and whistles. I probably should have just rented something though because now it just sits in the driveway... upside is that it's already worth more than I paid for it so if I let it go it won't be devastating from that perspective. I haven't driven it since we got back from Minnesota because I don't want to be lured into it...



When my wife and I bought our Q5 I really wanted a Cayenne diesel but she didn't want to spend more to get one. The Q5 is an incredible road trip car and is a bit quicker than a Cayenne/Touareg because it weighs a thousand pounds less. Ideally, I think I'd still like to pick one up, sell the RS3, Q5, and Vanagon and get back down to a three-car household again. Once we move I can see if there are other projects I'd like to get to based on the amount of garage space we have

My automotive life seems to have come full circle and if I end up with the Avocado, my truck, and a Cayenne it's the same fleet I envisioned 3 years ago, lol.