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01117 / Restoration / Phase II / Engine & front Suspension

 
Old 05-26-2019, 01:54 PM
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Sharp eye -Obe Wan. I had to remove the grommet to extract the pod. I had just reinstalled it before this photo on the ignition (so as not to loose it).
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Old 05-27-2019, 06:54 PM
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Looking good !
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Old 06-21-2019, 02:49 PM
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For those old enough to remember 1/24th scale Revell model cars..... this is the 1:1 equivalent in interior reassembly for the 928. Creative Audio (Brea Calif) just finished the repair and cosmetic refurbishment of the original Blaupunkt radio. This was the last item needed before reassembly. HVAC control unit got a good cleaning and reapplication of the grease, new *****, new microswitch and the sourcing of the critical gear that drives the fan speed no. display. Clock was rebuilt by North Hollywood $peedometer. Shifter console bezel is the new rev III 3D printed part.


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Old 06-21-2019, 03:01 PM
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The 1978 only console has the narrow shifter bezel. The remaining area on the 'floor' of the console was covered in leather. Really, really thin leather -dyed black. After an extensive search I found the correct stuff in Canada. I have a lifetime supply as I had to buy the whole cow. If you are restoring a 1978 and need some. I can set you up for the cost of packaging and shipping. Here are the details.






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Old 06-21-2019, 03:25 PM
  #125  
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I need some for Number 11!

Nicely done!
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Old 06-21-2019, 04:02 PM
  #126  
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Olmann,
Send me your address details via PM and I will mail you out one.
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Old 06-21-2019, 09:55 PM
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The HVAC registers on 928s get droopy and will not hold a position. There is a solution. BMW makes a great NVH tape that kills interior squeaks between metal and plastic parts. A small piece was placed on both sides of the rotational center on each register. The results are quiet and smooth action while holding any position.


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Old 07-06-2019, 04:48 PM
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Default 001117 / Phase II is Finished / mop up details

Phase II is now officially finished. We put ~150 miles on the car and did a shakedown on the drives verifying that all HVAC / lighting / Wipers / etc. worked. The A/C is blowing cold and the heater works. The antique potentiomenter for the instrument cluster lights had to be soldered up to solve the open circuits with the swadged rivets.

The 'rebuilt' Marchal alternator from Ebay went to 0 volts output after 100 miles. So it went for a proper rebuild with new copper windings, new diodes, new regulator and bearing set. Star Electric in Monrovia Calif. did the second rebuild. They will still take rebuild project on, as he still has access to the French parts. This took three weeks and $390.00. Star puts a load on all finished units and provides the attached final test printout. We came in close to the OEM spec at ~88 amps output.






Other adjustments after a few test drives was aligning the shifter in the rectangular cutout in the drive tunnel. I inspected 00143 and both that car and 001117 had the shifter shaft is too far to the right side of the drive tunnel. i.e. the shift selector shaft rests too far to the right side, creating the crash to the bezel every time you select 4th or 5th Gear.


The "fix'' is to slot the two holes in the drive tunnel (that holds the forward shifter shaft) and allows the entire shaft assy to slide to the left, nailing the placement of the shifter in all six positions without banging into the shifter boot bezel / frame.
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Old 07-08-2019, 12:50 AM
  #129  
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Default Phase III painting project / 001117

Phase III will be to paint the car. Key phrase here…..ourselves.

This is the main event in purchasing this project. Doing a 'complete' paint job once in your life. This will be done with the same team, who, as I learned after starting 001117, had the same bucket list item of doing a ‘complete’ at least once in their lifetime. So here we go.....

This is exterior only repaint with very little jamb work. Almost all panels on 001117 have the original paint, which is ideal for preparation.

We have negotiated an illegal 4 week sub-lease at an undisclosed location with a landlord that prefers to remain anonymous. This is a quiet industrial complex and the facility has a has a compressor and single post lift. Its ideal for the dusty work of block sanding and priming.

At this location over the next four weeks we will sand and apply high build primer to all exterior surfaces. The sequence is specific -to sand off the original clear coat and silver base coat leaving all of the fully cured original primer and galvanized treatment intact. Polyurethane bumpers will be media blasted first. The entire exterior will get primed and block sanded. Then again –applying more primer as required, followed by another / final block sanding.

001117 will then be transported to another location for long term curing of primer. At this second location we will spray based coat and clear coat in a professional spray booth.

The goal of the painting project is to replicate the factory finish as close as possible. The original paint is Silver Metallic / Z2. Very specific attention will be taken in each area of preparation leading up to the application of base coat / color.

We are not professional painters or autobody repairmen. Given that, our expectations for the finished results are very high. We will be using many common best practices in the autobody industry, paying extremely close attention to paint chemistry and mixing instructions and well as using high quality materials and equipment.

Don’t hesitate to chime in if you want to contribute your experience on items specific to painting a 928.

Disassembly has started and we have the first two surprises-
First, the upper door trim takes lots of thin edged special tools and patience to remove the extruded aluminum trim at the top of the doors. Note to self not to repaint the lip that grabs this trim edge.



No. 2 the flush rain gutter area on the steel roof panel (both sides) has no etching primer. Nothing. This area is a clear line raw metal and covered in surface rust. Very surprising given the other extremes Porsche went to in rust protection in other areas. This will get treated and properly sealed. The gutter trim strips will be painted off the car.




This is test area for sanding. The clear coat and original base coat have been sanded away on the top right corner of the drivers door. This revealed the virgin primer that has been fully cured over 41 years.

Last edited by mit Wasser; 07-08-2019 at 03:04 PM.
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Old 07-10-2019, 01:38 AM
  #130  
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Default Lightweight 928 gets transferred to the undisclosed location

Big night. Got all the trim off the car earlier today. Reinstalled the alternator and some Ghetto door handles. 5 gallons of gas. Off the jackstands and up the freeway to the paint shop. With the bare minimum.....safety wired holding on rear tail lamps and 1 bolt dangling licence plate.




The only thing that looks any good in this photo is the door gaps. Rear quarter windows will remain in place. The gaskets have been cut away enough to spray the gutters of the quarter window.





Safety tucked into the shop at the undisclosed location. Ready for a serious cleaning and then masking.
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Old 07-11-2019, 08:05 PM
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I'll bet its a blast to drive with all that weight stripped off
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Old 07-14-2019, 11:22 PM
  #132  
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The 928 lightweight was much quicker and louder. Motor sounds better with no interior.
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Old 07-14-2019, 11:28 PM
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Default Preparation for sanding

001117 had a few small dents and we really don't want to you any filler on the car.

With the passenger door gutted. Mike from Ultimate Dent Removal did an exemplary job of removing all the dents. There was nine small dings in the door.

Mike made quick work of removing the dent in the hood with single tool working from the inside of inner hood panel. The dent is 10 inches from his thumb.


Last edited by mit Wasser; 07-15-2019 at 12:51 AM. Reason: adding photos
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Old 07-15-2019, 12:22 AM
  #134  
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The left front fender was replaced by the PO in 2015. It was a used fender from 928 Intl. The PO's body shop put silver directly over the prior metallic red. What I did not know was how much red paint was on the fender. This panel has to go to zero and start over.

So we had to remove all the paint on this one panel. All of the remaining panels have only the original paint. So here goes....




This is with one quart of aircraft stripper. We will need a gallon to get all the red paint off. Here is a short video of how fast it works.....


Last edited by mit Wasser; 07-15-2019 at 12:45 AM.
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Old 07-15-2019, 12:25 AM
  #135  
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Default some shop humor......


classy joint......
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