So I finally got a 928
12-24-2014, 10:06 PM
#31
Rennlist Member
02-18-2015, 11:39 PM
#32
Intermediate
Thread Starter
So it's been a while but I'm sort of getting back at working on the car. My family suckling me during the holidays followed by getting my semester sorted out and then it starting, my getting laid up in the hospital a bit when my appendix decided to go loopy, and finishing making an array of props for a play have really set me back!
A handful of work has been done over this time but nothing monumental. I've just been trying to get it rolling so I can start working out more of the details while I get to know the car a bit more.
So far I've got just about all the parts I need, just waiting for the brake master cylinder to arrive. The manifold has been taken off mostly for need of getting all the debris out, including a large lizard skeleton(will post pics when I can). The radiator is out because it was easier to flush that way and that about sums it up, I also beat the the bent sway bar link to near perfection and it fit perfectly. Electrically I've just cleaned contacts and Identified bad relays.
Now the things that have me troubled and could use help on;
I was going to take the injectors out to ultrasonic clean them but I can't seem to take them off their pipes without getting to the point where the metal starts to give, I want to paint the whole manifold and figured it'd be better with them removed as well.
The EGR was gracefully removed by the previous owner, in other words the pipe was cut, crimped, and the edge welded. Would it be helpful to have that reconnected or should it just be neatened up.
What is supposed to be connected to the lid of the "oil can"(black yellow **** for tightening, don't actually know what to call it)? From photos, and common sense, I've gathered it should have a hose going somewhere but don't have a clue where.
I've got to change a lot of hoses in general, radiator air pump vacuum etc..., and will take any advice related.
I really want to get this thing rolling soon because I need the motivation, and not just for the car. I know once it's rolling I'll get working on everything much quicker, even if that means going with just the front seats bolted in and the rest of the interior stripped!
A handful of work has been done over this time but nothing monumental. I've just been trying to get it rolling so I can start working out more of the details while I get to know the car a bit more.
So far I've got just about all the parts I need, just waiting for the brake master cylinder to arrive. The manifold has been taken off mostly for need of getting all the debris out, including a large lizard skeleton(will post pics when I can). The radiator is out because it was easier to flush that way and that about sums it up, I also beat the the bent sway bar link to near perfection and it fit perfectly. Electrically I've just cleaned contacts and Identified bad relays.
Now the things that have me troubled and could use help on;
I was going to take the injectors out to ultrasonic clean them but I can't seem to take them off their pipes without getting to the point where the metal starts to give, I want to paint the whole manifold and figured it'd be better with them removed as well.
The EGR was gracefully removed by the previous owner, in other words the pipe was cut, crimped, and the edge welded. Would it be helpful to have that reconnected or should it just be neatened up.
What is supposed to be connected to the lid of the "oil can"(black yellow **** for tightening, don't actually know what to call it)? From photos, and common sense, I've gathered it should have a hose going somewhere but don't have a clue where.
I've got to change a lot of hoses in general, radiator air pump vacuum etc..., and will take any advice related.
I really want to get this thing rolling soon because I need the motivation, and not just for the car. I know once it's rolling I'll get working on everything much quicker, even if that means going with just the front seats bolted in and the rest of the interior stripped!
02-20-2015, 10:15 PM
#33
Drifting
MAN BITES SHARK!
WELCOME to the insanity, fellow 928 owner! Great looking car for a 36 years old. I like the Porsche crest on the seat back. The paint looks OK for a '79, mostly dirty? I"m keeping an '83 EuroS alive and all my friends think I'M NUTS.--Till they ride in it. If you are as stoked about yours as I am with mine, your friends will think you'er crazy too. As for getting it running, your "insanity" will have you running in 20 directions at once. BTDT. The only way to do it is to make lists, and lists within lists. EX-- #1 A-cheap stuff- a1 change Oil, coolant, brake & steering fluid (note P.S. uses ATF!) Air cleaner, (I've heard that sharks don't like K&R filters)change trans lube?--- a2 change All the belts and rubber hoses.>>>>a4 change all fuses, clean grounds, new Battery? re build 14 pin connector. #2--Engine- A- Front end. a1 timing belt/water pump ----B- intake refresh. Vacuum hoses, gaskets, clean throttle body ---(etc) #3 Front end----A. brakes B. shocks C. steering rack. And so on.
It's almost like you make a flow chart and check things off as you do them, otherwise it can get kind of daunting if too many things are "In Progress" at same time. You can get overwhelmed by "while I'm in there"s. an example-- to change the engine mounts, you have to remove the steering rack,. So if your rack leaks, like mine does, you do the mounts at the same time. And since you have it in the air with the rack out, why not do the shocks now too? How bout a new sway bar? Ect. Ect. BTDT too.
Replace the bent sway bar. By bending it back, you've stressed it in both directions. Not a good thing with a part that gets twisted when in use.
Once you get it up & running, your friends will understand why you did "All That Work"
Keep posting progress notes and everybody on RL will steer you right, Just have they done for me. Remember- Pictures, pictures, pictures,
It's almost like you make a flow chart and check things off as you do them, otherwise it can get kind of daunting if too many things are "In Progress" at same time. You can get overwhelmed by "while I'm in there"s. an example-- to change the engine mounts, you have to remove the steering rack,. So if your rack leaks, like mine does, you do the mounts at the same time. And since you have it in the air with the rack out, why not do the shocks now too? How bout a new sway bar? Ect. Ect. BTDT too.
Replace the bent sway bar. By bending it back, you've stressed it in both directions. Not a good thing with a part that gets twisted when in use.
Once you get it up & running, your friends will understand why you did "All That Work"
Keep posting progress notes and everybody on RL will steer you right, Just have they done for me. Remember- Pictures, pictures, pictures,
02-21-2015, 12:02 AM
#34
Rennlist Member
I just replaced the positive cable from the battery to the starter on the Stepson. It has made a world of difference in the way my starter spins. A new Porsche cable was somewhere around 200 bucks. I used #0 welding lead purchased from my local welding supply. The welding supply also crimped on the eyelet end that they supplied and the whole shebang wa only $45. I would recommend this over soldering an extension onto the existing positive battery lead
02-21-2015, 07:12 PM
#35
Race Car
yup
I had similar results on a 928 a few years ago, ordered #0 cable from summit racing....probably is the same coming off the spool as the welding lead, who knows. Suppose it might have a different insulation- the way it is tucked/clamped into the body seem gave me pause re: chafing. Definitely dropped the resistance some, noted much improved starter performance.
02-24-2015, 01:31 PM
#36
Intermediate
Thread Starter
So here are a few pictures
Since I only have the photos I've taken on my phone I figured I'd go ahead and upload whatever I had. The lizard looks like he had found himself a nice place to rest, and yes I'm aware of the condition of the spark plug cables. The green 928 is the same green I'll be using on a few things under the hood and here and there throughout the car but i just thought it looked great on the numbers! I'm going to have to go ahead and become a paying member so I can upload more.
My master cylinder got here and I was going to get into it but when I got a good look at the booster, which my brother had taken to a mechanic and they had said it was fine and I was going to paint, I noticed it had a lot of rusty grime and am now considering getting a new one. I wouldn't mind putting it back in to replace later but would hate to go through the ordeal all over again.
The extension I added to the main positive cable was a welding cable and I did a braided solder, braiding and soldering the inside strands then moving outward until the entire braid is soldered from the inside out. I trust it.
And the real pain in the *** right now is the oil drain plug. Looks like the PO had stripped the oil pan threads and reattached it with something like JB weld. So when I went to take it out to drain the engine it turned but wouldn't budge outward, after a fiasco with a socket wrench and vice grips it came out and we realized what the PO had done. Now I'm going to have to see about getting a tap in the right size and a replacement plug, maybe I'll but a drain valve in to ease oil changes in the future?
My master cylinder got here and I was going to get into it but when I got a good look at the booster, which my brother had taken to a mechanic and they had said it was fine and I was going to paint, I noticed it had a lot of rusty grime and am now considering getting a new one. I wouldn't mind putting it back in to replace later but would hate to go through the ordeal all over again.
The extension I added to the main positive cable was a welding cable and I did a braided solder, braiding and soldering the inside strands then moving outward until the entire braid is soldered from the inside out. I trust it.
And the real pain in the *** right now is the oil drain plug. Looks like the PO had stripped the oil pan threads and reattached it with something like JB weld. So when I went to take it out to drain the engine it turned but wouldn't budge outward, after a fiasco with a socket wrench and vice grips it came out and we realized what the PO had done. Now I'm going to have to see about getting a tap in the right size and a replacement plug, maybe I'll but a drain valve in to ease oil changes in the future?
03-05-2015, 02:37 PM
#37
Intermediate
Thread Starter
I've upgraded my membership so I'll be posting many more pictures!!!
I guess I took a leap and decided to go ahead and pull out the k-jetronic and I'm glad I did. Even though I tried shoving a vacuum hose around it to clean out all the debris that was left from what I'm guess was a rats nest it still had a lot! Plus I get to give it an even more thorough cleaning, i was about half way done in the pic.
The shelf is my entire parts sorting system, everything in its place and a place for everything(ignoring randomly scattered tools)
The interior is still in its... exposed state, and I think it'll stay like that until I finish up under the hood.
More photos to come!
I guess I took a leap and decided to go ahead and pull out the k-jetronic and I'm glad I did. Even though I tried shoving a vacuum hose around it to clean out all the debris that was left from what I'm guess was a rats nest it still had a lot! Plus I get to give it an even more thorough cleaning, i was about half way done in the pic.
The shelf is my entire parts sorting system, everything in its place and a place for everything(ignoring randomly scattered tools)
The interior is still in its... exposed state, and I think it'll stay like that until I finish up under the hood.
More photos to come!
Keep at it
03-08-2015, 09:12 AM
#41
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03-20-2015, 01:33 PM
#42
Intermediate
Thread Starter
Getting some more stuff done
So here's the unceremoniously removed EGR, I'm going to work on that today so I
should be posting the after photo tonight or tomorrow.
The intake manifold might be too much green but I'm sticking with my decision. Partially because I don't want to go through the painting process just yet.
For the air pump I just wanted something other than the old filter assembly so I
got a breather filter that had a similar diameter hose fitting and it looks good.
On that note, the smog pump system has that vacuum valve controlling it with
what appears to be just a blow off for when it isn't blowing into the engine, or is that extra tube supposed to go somewhere?
I was thinking of just putting a small filter on it too, it had a lot of bugs in it when
I took it apart.
I've also got a bad fuel line going from the soft line to the k-jetronic, not sure if
it's the return or sender. I've got some macro photos and I thought you all
might enjoy looking at a pin hole formed by rust.
Where do I get this line?
should be posting the after photo tonight or tomorrow.
The intake manifold might be too much green but I'm sticking with my decision. Partially because I don't want to go through the painting process just yet.
For the air pump I just wanted something other than the old filter assembly so I
got a breather filter that had a similar diameter hose fitting and it looks good.
On that note, the smog pump system has that vacuum valve controlling it with
what appears to be just a blow off for when it isn't blowing into the engine, or is that extra tube supposed to go somewhere?
I was thinking of just putting a small filter on it too, it had a lot of bugs in it when
I took it apart.
I've also got a bad fuel line going from the soft line to the k-jetronic, not sure if
it's the return or sender. I've got some macro photos and I thought you all
might enjoy looking at a pin hole formed by rust.
Where do I get this line?
03-20-2015, 05:49 PM
#43
Rennlist Member
Looks like good progress.
-If your clutch is always dis-engaged with the slave out, I think you are going to have to drop your clutch. Happily that is pretty easy compared to getting clutch and brake masters in and out. Might as well do it now so you can figure out what you need.
-Lots of times when folks climb in to early 928 projects they make good progress until they get to the fuel system. The CIS system gums up and the major components cause problems that can be hard to resolve and the parts are expensive to replace. Also, many amateur mechanics can never quite get their brain around how the system works, and how to repair it. But, for the most part, they can be fixed pretty cheaply with enough time, understanding and effort. My suggestion is that you do not wait too long to start exploring the system and understanding the condition of your parts and what you need to do. You can do most of the tests you need to do with the intake off or even with the motor out.
-If your clutch is always dis-engaged with the slave out, I think you are going to have to drop your clutch. Happily that is pretty easy compared to getting clutch and brake masters in and out. Might as well do it now so you can figure out what you need.
-Lots of times when folks climb in to early 928 projects they make good progress until they get to the fuel system. The CIS system gums up and the major components cause problems that can be hard to resolve and the parts are expensive to replace. Also, many amateur mechanics can never quite get their brain around how the system works, and how to repair it. But, for the most part, they can be fixed pretty cheaply with enough time, understanding and effort. My suggestion is that you do not wait too long to start exploring the system and understanding the condition of your parts and what you need to do. You can do most of the tests you need to do with the intake off or even with the motor out.
03-23-2015, 11:45 PM
#45
Intermediate
Thread Starter
Looks like good progress.
-If your clutch is always dis-engaged with the slave out, I think you are going to have to drop your clutch. Happily that is pretty easy compared to getting clutch and brake masters in and out. Might as well do it now so you can figure out what you need.
-Lots of times when folks climb in to early 928 projects they make good progress until they get to the fuel system. The CIS system gums up and the major components cause problems that can be hard to resolve and the parts are expensive to replace. Also, many amateur mechanics can never quite get their brain around how the system works, and how to repair it. But, for the most part, they can be fixed pretty cheaply with enough time, understanding and effort. My suggestion is that you do not wait too long to start exploring the system and understanding the condition of your parts and what you need to do. You can do most of the tests you need to do with the intake off or even with the motor out.
-If your clutch is always dis-engaged with the slave out, I think you are going to have to drop your clutch. Happily that is pretty easy compared to getting clutch and brake masters in and out. Might as well do it now so you can figure out what you need.
-Lots of times when folks climb in to early 928 projects they make good progress until they get to the fuel system. The CIS system gums up and the major components cause problems that can be hard to resolve and the parts are expensive to replace. Also, many amateur mechanics can never quite get their brain around how the system works, and how to repair it. But, for the most part, they can be fixed pretty cheaply with enough time, understanding and effort. My suggestion is that you do not wait too long to start exploring the system and understanding the condition of your parts and what you need to do. You can do most of the tests you need to do with the intake off or even with the motor out.
I've got the CIS figured out theoretically
I've pumped fuel system cleanerthrough it and the small filters for the injector lines all seemed clean so I'm
hopeful that won't require a rebuild before I get this on the road at least.
I've got new master and slave in but haven't bled them or the brakes yet. but it
turned out the old slave was jammed and was just holding the clutch slightly
disengaged.