pcar928fan

As the dies that press the panels get old they no long press them perfectly. The shop that just finished my '95 (post deer hit) ordered a hood, got it all ready for paint, fitted it and said, "screw it...lets get another 'cause this one SUCKS!" The next one was EVEN WORSE! They spent 7 HOURS making the first one work!

S4ordie

I had two issues with this car. There was repaired front end damage as reported by the PO, albeit under reported. Greg Brown had noticed something odd about the panel alignment when he was tearing down the drivetrain. Once the car got to the shop it became obvious there as an almost 2 inch (5 cm) compression on driver's (left) side of the car.

The parking sign the PO reported the car had hit was significantly much more significant. The body and paint work completed by the PO to repair the damage was neither correct nor safe. To be clear, the PO paid good money to have the car repaired, the quality of the repair was sub par. The paint was adequate, the tweaked and shimmed replacement body panels not readily noticeable. Though the car had been aligned the day before I accepted delivery of it, there was a noticeable drift in the steering at any speed above 40 mph (65 kph).

So what to do?

As this project had already had much $$$ invested in it by this point it was determined to have the front end repaired. This required the expertise of Ron Ruff of European Collision Center in Downey, California, to break out his best skills to save this car and not only to repair it but to make if structurally as sound as it was originally manufactured. This car after all would be carrying me and my family. Ron sourced one of the very last remaining 928 body jigs. He used it to straightened and aligned the entire car back to original specs. With concerns about the structural integrity of the front cross brace we elected to remove (cut out) the entire left front assembly and to replace it with an sound section from a donor car.

This was a massive repair project, Ron is a perfectionist so the work was long, extremely precise and expensive. Everything about this project has been to make the car as good as new or better. Having a structurally compromised front end would have been incongruent with the philosophy of this project.

polecat702

When Dan has a project, less than perfect won't do! Everything he does is 110%.

Would you all believe that when my 87 was totaled, he offered to drive the Zycamalot car to Vegas for me to drive for the summer, till I replaced it with another 928. To be honest he's as close to being a real brother as I could ever have.

I can't wait to see the turquiose car in person. I know it's going to be spectacular, and it won't be a garage queen either!

kiesan

This is without a doubt the coolest car that ever used to be mine. Good work Dan!

As the po, I feel terrible about the repairs that have had to be undertaken in order to achieve perfection. The details of the crash were reported to me by the po to me, the person who crashed it. This was January 2007. Then I showed the car in its's damaged form to what I thought was the best body shop in Seattle and they told me his story jived with the damage the car had. Then I left it with them with instructions to do whatever was required to make it right. Both times I aligned it, neither shop mentioned anything that would indicate a frame issue or other more serious problem.

Seattle needs a paint/body guy like this Ron person

S4ordie

My comments were not meant to be an indictment of you Kie but that many body shops repair for an acceptable visual outcome that may mask underlying issues. This car will be as right as new, or better, in all ways. It has been a long slog but will be worth it.

Project has been underway for more than 3 years now.

S4ordie

Rob Edwards stopped by Ron Ruff's shop yesterday to drop off components he had serviced, cleaned, repaired or refreshed. He took these pics of a couple of body panels after block sanding. They do this to knock down any high spots before buffing to a mirror like finish. After that Clear will be sprayed followed by reassembly of the the painted components (hood/bonnet, hatch, headlight buckets, side mirrors, lower rocker trim panels, front/rear bumper covers, ....)

S4ordie

More pics of block sanding the main body of the car.

Landseer

Jeeeez.

So that's how its done RIGHT.

Wow.

brutus

Nice to see that they removed the wheels and used a dolly to move the car around . Few shops do that and just blow over spray all over the wheels. Nice touch.

AirtekHVAC

Wow....

Arnoud

Thanks for continues posting of the pictures from this work in progress: beautiful and top quality restore work!

S4ordie

Project Complete!

It’s been a long time coming but the end of the “Refresh” project has finally come to a close. The goal was to end up with the penultimate 928. To me, this meant using only the best people and their services and products whenever possible. Virtually every nut, bolt, fastener, widget, bulb, connector, etc., was either replaced with new, rebuilt to better than new, or replaced by a custom fabricated piece, part, system. The result is indeed the penultimate 928.

What started out as an unusual colored - Turquoise Metallic – 1991 S4 with some minor paint and alignment issues - evolved into a full tear down and rebuild of the car. To get a sense of the charter for this project one must mentally ride your favorite time machine back to the 1970’s and the opening narration of the hit TV program - Six Million Dollar Man, “Gentlemen, we can rebuild him. We have the technology. We have the capability to build the world's first bionic man. Steve Austin will be that man. Better than he was before. Better, stronger, faster.” In a similar way the efforts, contributions and technologies put towards this project have produced a "Better, stronger, faster" 928. Some might even say, the best 928 in the world.

There are so many great people who have contributed to the success and culmination of this project. Much in the way actors at the Oscars often state during their acceptance speech, “there are so many people to thank for this success but I am sure I will forget someone. Please forgive me.” I am about to do the same. I can categorically state that every vendor on Rennlist has product, services, or both, in this car. Additionally, many hands have touched this project.

I sometimes hear people say, “It’s just a car Dan. It’s not a living thing.” This is technically true, but upon not very deep introspection, this car, this inanimate thing, has been the catalyst for forging friendships and relations I will have for the rest of my days. So though it is just a car, it represents something very personal and life enriching to me. Perhaps others in some measured way. Regardless, it has been a journey, started with purchase by me but ending with a small army of contributors and friends. How great is that? Really great I say.

The contributions to this project by others has been immense. Certainly Greg and Mary Brown of Precision Motorwerks have contributed the most to the oversight and transformation of this car. Additionally, there is Mark Anderson and his team at 928 International, Run Ruff and his cadre of body and paint experts at European Collision Center, Paul and Linda of Design Paul Champagne, Bob Budd of Classic 9 Leather Shop, Tom of Collins Auto Upholstery and many other parts providers; Roger’s 928sRus, Hans Servaas and his audio products, Constantine’s Black Sea Engineering “Super Clamp” and torque tubes, Carl’s 928 Motorsports, and others. I thank you all for the commitments you have that further the lifespan and capabilities of these fine cars.

I would be remiss if I did not identify the selfless interventions and help of those with specialized skills or knowledge: Jim and Suzie Corenman (Sharktuner maestro, CDR-220 upgrade and perfect shuttle drivers), and of course, Rob Edwards, a person whose willingness to step in to help accelerate progress and to do many unique things, like dash reassembly, LED replacement for all dash pod displays, rebuilding window motors, etc., as well as, clearing out his own garage in order to house my car for extended periods, even when he and his family temporarily moved to another house while their’s was being remodeled. My appreciation and gratitude is beyond ways I can ever adequately express. Thank you, thank you, thank you. Thank you to all.

The project in very brief summary:

Drive Train: Greg Brown (Precision Motorwerks): 6.5 liter stroker engine with custom intake/manifold porting as well as oil scavenging cylinder modifications. GB’s custom stainless steel headers and exhaust system. Performance rebuilt transaxle. Includes Constantine’s Super Clamp and rebuilt torque tube.

Wheels, Brakes, Suspension: Ultra rare 9jx17 ET70 Cup II wheels on front. Mille Migilia 18x10.5 Cup II replica on the rear. Brakes: upgraded new GTS components with racing grade rotors. Suspension: New Bilsteins on all four corners.

Interior: Custom Pascha Paul Champagne seats console armrest, door panels, steering wheel, shifter and CPES impregnated rear quarter panels. Bob Budd dash, pod, center console with exterior matching French seams. Collins Auto Upholstery dynamat, carpet and misc panels. Sunroof delete headliner is stock factory unit.

Accessories: Greg Brown custom AC system with 2nd remote condenser plus Roger’s upgraded fan motor. Jim Corenman upgraded CDR-220. All lights upgraded to LED. Headlights are upgraded (new) H5’s. New OEM complete seat belt assemblies front and rear. Hans Ser Vaas’ Sharkwoofer and door speakers. Fully integrated and stealth installed Passport 9500ci radar. Jerry’s very stout ABS wheel well liners.

Body and Paint: Ron Ruff integration of factory GTS side mirrors, rear quarter panels and sunroof delete. All components are factory and sourced from Germany. Paint is the almost NLA acrylic enamel that dries very slowly but is the same as the original hard factory paint. Every seal/bead is new (doors, hatch, receiver, hood liner, bumper covers, etc.

Here are pics of the final product….

Rob Edwards

Who hooned it across the lawn?

syoo8

This car is the dream car for almost all of us. Certainly me.

Many, many congratulations to you.

S4ordie

Made a few days earlier when a 30 ton crane rolled over the yard to lift a couple of 8,000lb / 3500kg boulders from my yard to the neighbors. I hated them, he wanted them. Cost me nothing but a truck bed of dirt to fill in.