Original Burgundy interior will be replaced by a dark blue 968 one:





Some side projects:

Belts change and Euro LHD lights for japan import Silver Rose



Belts change for 968; also imported from Japan



Removed power windows mechanism. Usually un-serviced 944 windows are so slooooooow. Fortunately 944 system is really easy to remove, took about 5 minutes per door. Then just put systems to parts wash them properly, lubricate well, and install back



[img]http://[IMG]http://i5.photobucket.com/albums/y170/olli951/DiamondBlue951/028909e9.jpg[/img]

As a "side project" changed belts to a 951 & 944. Quite hot work to do when it was about 30 celsius (summer 2011) and even more in the direct sun light



My 968 turbo splitter mould is also ready. Just finished a splitter for a friend. Notice a old barbecue grill frame, which is very handy when you do some fibreglass work



Original spoiled stereo wires were restored and they have now Iso-connectors. The entire wiring harness is now totally restored.
As a side project i fabricated a 968 Turbo front splitter for a friend's 968.

Some primer



after that i added 5 layers of Midnight Blue Metallic and 5 coats of clear coat
and installed splitter.






Made some glassfibre stuff. One new Strosek style side skirt mold ready, one to go tomorrow. Will fabricate a pair of side skirts for son's 951. Mold turned out fine

Washed my BMW project car. Bought it three years ago for 100€




Been busy servicing other people transaxle models. Chipped first a Midnight blue 968. Then got a Speed Gelb 968 for oil pan gasket change.

Sky high




Like junior's tractor..



Borrowed a nice engine support from a friend of mine



Had to stop gasket service when i had to chip another speed gelp 968. This time a nice CS model

CS have a Shark sifter which felt nice when i test drove CS



received black carpet dye from UK. The plan is to dye burgundy carpets black.



Too much side projects

My son got his new suspension




Changed belts to a 968. 14th belt change during 2011...
Was real easy with this hi tech tool i made..





Son bought few parts for his projects rear axle

More re-plated parts for son's project.



Also some "left over" parts, like manual window mechanism, we are not going to use in project. Just had all parts hanging around re-plated at the same time, after all it's really cheap to plate stuff

we delivered quite a lot of different parts to powder coater's. More or less all necessary parts are finally getting paint on them. Son is here cleaning intake to be powdercoated. He removed a heat insulating which was added there.




We didn't want to powdercoat the cam tower. Local paint store mixed us a can of heat resistant paint, RAL 7016. Intake is currently on powder coater's to get the same shade of color.Color is much darker in live.

project car's and some other stuff came home from powder coaters



Friend machined some paint off






Some semi-solid transmission carriers on their way.




Final product looks like this

My friend Harri designed this "Neva-tank" catch can, Here's unfinished unit which can be bolted on directly to the place of the original air cleaner box with attachment hardware included.
Harri has not decided yet will it be polished,anodized or powder coated. If the manufacturer is willing to build more of these we will like to have a similar "Neva-tank" installed into son's project 951.



We started a BMW project for a friend.
Three Porsche men with Beemer parts



Start of the Beemer brake project

First we pressed in the bearings



And then E30 M3 5-lug hub with E46 rear disk



Test fit Boxster caliper



Then we measured dimensions for the adapters



Front end need some special parts to be able to use E36 5-lug hub



With 16" E30 M3 wheel there is a lot of space with Boxster caliper. Even Beemer 15" wheel will work. I suppose we are going to use bigger front calipers



Got to have similar brake set up for my own E30 Beemer. Picked up rear disk brake control arms yesterday (my Beemer have rear drums)

Project cars orginal front seats were in quite bad condition. Son have a complete 968 interior which is going to replace the original one. Someone asked me if this burgundy interior is for sale, so i decided to bring it back to live.

Starting point





Cleaned and washed



Ready for sale.

Since Burgundy is not a color to go with we had to change carpet color as well.

Some of the original carpets before the treatment.



Adding some carpet dye (Valeters Pride)





After two coats. Will need a third one. Burgundy is really difficult color to dye over with black.

Before we can start bolt on under garriage parts, we just have to take care one cosmetic thing. Since we have a lot of red anodized parts (see color from pictures) our friend Antti (9Products) has made for us,




GAZ blue just won't fit. Because of that we put GAZ's to parts



and placed blue anodized parts to citric acid bath.



When anodized coating is removed, we will have parts re-anodized to same red as parts my friend have made for us.
We also found out the original anodized blue was not that good, so we hope we can have also a better surface.

Removing blue anodized with citric acid was way too slow. It removed color a bit, but i didn't want to spend too much time on this



So i changed to little bit heavier acid....



About 10 minutes and i got what i wanted



We started to remove the very last things from car's bottom. Since we are going to install ABS system, old non ABS brake lining was removed like fuel lines as well. We already have a replacement ABS lining . One reson to remove everything is to have better possibility to make a proper wash up. Now it's just too dirty. Son also removed turbo side skirts which are not needed anyway, since they will be replaced by Strosek style units.

Son removing the side skirts





Old brake & fuel lines



Needs to be washed up

Got Gaz coil over parts back from platers shop. Now they are plated according to our color scheme match better to 9Products our friend has made for us.

Before:



After:



Removed the door handles. Son bought a set of 968 handles from Scotland



He also bought a cheap LVLP type of paint gun (i suppose it's a Sata clone). We are more or less ready to paint the project's bottom. We are also starting soon to prepare the body for complete overspray, which will be done by a friend of ours.
Diamant blau (Diamond Blue) is a nice color.Upper picture is taken without the flash lower picture with flash




I started to fabricate 928 glassfibre sunroof



Top skin mold almost ready



Another glassfibre project is a 968 hood for a friends race car.

We removed the fuel tank. It will be easier to clean the undergarriage when it is removed. Also easier to wash the tank.





Torque tube is more or less ready to be painted, we will also change the bearings.



Son assembled Gaz coil overs. Now they are according to our color scheme red. Job was done by the same company which our friend Antti uses for his billet parts. Since we have a lot of them, Gaz blue had to go





Son removing surface rust




rear bumper was removed, like diffusor as well



Bumper have a minor scratch, so it has to go. Luckily i have a new unused part reserved for repalcemet




Got transmission carrier from Antti. It's a special version with red bushings Commercially available version have black ones

Wash up time

Quite peaceful outside the garage



In action









Old (25 years) reliable pressure washer did it's job very well



Like a wet dog.....

Putting protective plastic on.





Applying some fresh Diamant Blau color to wheel wells & bottom







After 3 layers of base color it turned out quite nice. We added also 3 layers clear coat to wheel wells

Seems to me building a car is more or less washing & cleaning up parts

Next some arctic parts digging. I am going to pick up "new" brake lines (ABS) from a friends yard. Only problem is there's some snow (about 1m) surrounding 944 S2 which will donate those vital parts.)

S2 wreck in October (no snow....)




There is also a 951 which has already given to son's project 951 it's AC system and some other parts...
Restored AC unit on right taken from that wreck




Son's project 951 almost had a same faith. Here it is at the same yard when son bought it




ABS system will be a 951/S2/Boxster combo, so 951 ABS pump & "brains" will be replaced by a Boxster unit (With Tony G's help). Just bought a suitable ABS pump from UK.

First arctic digging session is over. Due the short time i had available, not much progress. Got to continue tomorrow.

There is the part donator



Shoveled some snow....




Had some good company as well

It was so warm, just -16C, so we decided to continue some arctic digging.
Went to friends yard with my son and another friend Juha, who owns a nice 968.
Empty shell is quite light. I suppose two man can easily turn it over. I was just there pretending to lift, but i suppose it was my son & Juha who actually did the job





Juha searching if there is still something usable



Here's Juhas fine 968 with Turbo splitter i have made

Received some parts from UK



Juha's new seats came with the same shipment



ABS pump came really fast from UK (thanks Steve). Now just need to get a special wiring harness from Tony.




Got a LOT of used 944 parts. Luckily some of the items were the ones we need for son's project. For example car's original streering rack was sold. We already had a replacement unit, but it was taken from an old ET car and it was also equipped with older style banjo bults etc. Now we have a correct rack, which was taken from 1990 S2. Just have to put it to the parts, clean it, send the body to re yellow passivated and put it back together with new seals etc. Should be as good as new. We will also have a new style non-leaking hose system for this rack

Plan is to have 951 rolling soon again, so it was time for some torque tube treatment.
We want to have new bearings in it, since most likely the current ones are original 24 years old. Removing saft & bearings is not a big deal, but we didn't want to spend too much time removing them. We loaded the tube to my car and drove to friends workshop. He have all necessary tools to accomplish this task in few minutes.

We came on a good time, since our friend was just doing the same overhaul to a 924 S tube



Modified clamp



Tied up



Starting to pull the saft out




Out. It takes less than 40 seconds to remove the saft



First bearing out



Changing the direction for two last bearings



All out. Two of them were a little bit shot. Total working time less than 10-minutes



General view from friends workshop




We also bought new bearings from our local parts store. Total cost of a rebuild tube is about 50€. We still manage to do even this task on low budget

Video

http://s5.photobucket.com/albums/y170/o ... ction=view¤t=dd842741.mp4

New bearings arrived. Now it's time for some TT restoration.



Started to restore TT . Did some minor fuel tank heat shield overhaul as well.

TT were cleaned properly, so it is rust free now. We wanted a bit better surface, so we put on some plastic filler



Some sanding




And it's ready for fresh paint



Fuel tank heat shield looked like this



After some aceton treatment



Polished item




Test fit new ABS pump as well

Some minor progress, too many side projects which are slowing down son's project.

Torque Tube got some rust preventive paint on it. Next step is to have black 2K epoxy on it



We started to restore the fuel lines. Some surface rust on them. I removed the old green coating and found out that steel line under coating was in very good condition. Now we are going to paint cleaned lines with 2K matt dark green paint. After that clear heat shrinkable tube "coat" will be put on it.

Cleaned fuel return line on left & un-cleaned main line on right



Two side projects finished. Changed right balance saft carrier to friends 968. Power steering pump bracket was broken



We also changed the belts at the same time and fixed leaking powersteering hoses



Happy owner (left) with my son



We also fixed worn front control arm ball joint of 944 S

I thought these tie wraps were NLA. A friend of mine needed few for his S2 and gave me a correct part number, so we ordered 20 straps for sons project as well.



Since it has a VW based part number, i asked from local VW if i can buy that as a VW part. Very helpful parts salesman looked from VW Etka and found out that part to be a "Porsche specific" and not available through VW in Europe. Only VW which still use it is a Brasilian made VW Saveiro pick up..... So in Brasil, you can buy 944 Tie Wraps directly from VW



Here's what have happened during the last two years. Project has been slow. We have done a lot of side projects and also since son is a student, money is always tight.