Ben006

Still going strong toward the first real drive !

Got some parts powdercoated for free !




I designed some stuff...

Brake duct to fit a 80mm hose to better direct the air to the disc.
It will be paired with new brake dust shields.

I removed the rear suspensions :


After two days... I found out that I left two bolts on the gearbox...


Gearbox on the floor !


Quick cleaning before opening it:


We cleaning the rear subframe at work :



Then I opened the gearbox once at home :
1st and 2nd were impossible to engage while moving !






1st and 2nd synchromesh are dead, so I'll replace them alors with the the other synchro rings and bands.

Good news ! I do have a LSD !

But... last time I drove the car I didn't feel it at all... so it probably needs a rebuild !

I got the tires, the rims, and the RDK plugs too... that means :



I love the look !

I then moved on to the gearbox itself :









I took the time to clean and paint some parts :






I removed the parking brakes shoes to take car of the bearings.


Everything is fine and moves freely.

Here is a comparison... 928 VS GT3RS


Today I cleaned stuff again !
Before:





During :


Done




And the gearbox case too :


Ben

Ben006

Hey !

I got a new printer



I'll be printing a lot of interior parts!

I finish cleaning the gearbox case. I didn't want to sandblast it... but I ended up doing it anyway... I'll paint it black Monday to protect the bare aluminum




Cleaned !



I received a zinc plating kit... so I removed and cleaned all steel parts I could easily access from the car !




Et woila :

I received 25L of distilled water, I will try my first parts this week !

It's my last month at the dealership ! So they made sure I would be here to do the clutch on this one !
I love the look of it (I don't love the 20cm wheel spacers though...)

This car is particular for me because its previous owner is also the previous owner of my dad's former 928, which made me like them in the first place !












I received the synchromesh and fitted them !



Then it's just a matter of piling the pinions back the correct way









I got all the parts back at home, ready to fit them back on the car !
After I do the zinc plating...

Also, I started to rresearch about arduino's, and boy it gives me some idea to simplify the the 928's electronics.
Headlights, tailights, and intrument cluster...


Ben

Ben006

The gearbox is almost ready !
I modified the return spring to have the lever centered :


Before
[youtube]0EJwwu-dIqA[/youtube]
Mod :
[youtube]-tOxl1fHeCw[/youtube]
Done
[youtube]PIgsL-vJ-1k[/youtube]




Replace the plugs on the back :


I got some good advice for the zinc plating and it worked well





Still some mishaps but you can always redo them!


I received some stuff for future projects too

Colbob

Ben-You my friend are an artist. I can imagine what the medical community could have benefited from your dedication and brain power. I feel that the next thing I do to my 928 will have you looking over my shoulder!

Ben006

Thank you
I don't think I have that much brain power, I'd stay I'm stubborn and resiliant ^^

Check that now :

I finished the clutch on the blue 928 at work, customer is super happy !




Driving it made me want to drive mine so bad

I printed a part of the new seat mount to check (and it checked good )


Put the diff back in :

And the covers :


I continu to plate more parts, the brake shoe plate took a lot longer...







Tomorrow I'll continue plating, and making shifters...

Ben

Ben006

Here is today's work !
















But...

It's the wrong ball joints !
Now I have to order S4 spindles éhéh

Pete in DC

This thread is really something else. Incredible amount of work.

Ben006

Thanks !

There should be even more very soon

But today was nice !
Best christmas gift ever !






4 Almost brand new 18" Panamera wheels !
They were at work on a rack for the last 11 years !

Ben006

Sooo, that's I left Porsche to focus on my business... It's going to be tough, but I'll make it

I haven't done much on the 928...
I ordered S4 spindles with reversed ball joints... I think it'll be safer for the track !
I also ordered tires for the panamera wheels, Kumho PS91. I loved them on the Boxster, both on dry and wet pavement, so they'll do well as street tires for the 928

I continued the zinc plating ! I'm almost done, only bolts and nuts to do !



Only a few nuts and bolts ^^



The car has to be able to move on its own by next month... so when the rain stops I will have to design the oil cooler support and airbox !
The rest like the interior etc can wait till I have another shop !


Ben

Ben006

Almost done with these !




So... my transmission mounts are ok, but old...
Yesterday I designed them, today I printed a test... soon the final version.
Will be steel with urethane inserts.






Just need to sort out a few thing like the tubes diameter and go !

I'll probably make engine mounts the same way


Ben

Ben006

Yay gearbox's in !

Ben006

Gearbox is filled, CV axles are in, even though I don't have the clamps yet...





I found another steering rack in good condition to replace mine.
I've heard of a guy that re-do 928 racks with a shorter ratio, I don't remember who it was !

I'll replace the parking brake cable... later !


I've been called to take a look at another 928...



She has some issues but nothing major, just need some love !



Tomorrow morning I'll get the parts to finish the rear end.



Once done, I'll do a quick tightening check around the car, and work on the oil cooler position.

Friday I got the keys to my new shop ! It's tiny but it's all I can afford and I love it !




Of course there was no way I would just get in and not redo anything...


I'll redo the insulation and roof, then fix the ground and paint everything. Metal structure will be black, ground light grey, and walls white.
I'll double the lights and install power outlet everywhere !

Ben

Darklands

Very nice place and warm.
I have my big space with my lift but there we work on agriculture machines with a lot of dirt and it's not isolated.
So I will finish a closed room with a new work desk, a washing table and storing space for engine and gearbox parts and work.

Light is new, all the old stuff must go and than I can work in clean Environment.

Ben006

Nice
It's always nice to work under a roof !

I picked up the isulation panels today. 600Kg of them...


And started to clean then paint the metal frame



I didn't pick up the 928 parts yet...

Darklands

A friend of me has in his shop on the floor rubber tines. Easy way to improve the floor.

https://www.google.com/search?q=werk...jyLdIJRVc8a0kM