Rebuild of my 1980 Euro S
05-23-2011, 09:20 PM
#91
Pro
Thread Starter
Plenty of small detail progress today, but they are small items not on my to-do list, so doesn't seem like much until I look at the parts storage shelves and see they are getting bare! Nice to have things coming back together, and able to work with clean stuff. Now I can work on it and not have my fingers get dirty at all!
Found out what people have talked about when it comes to rust in the washer reservoir tank - NASTY! Porsche missed a technical detail on that one! I managed to chip out the rusty sleeve, and followed someone's suggestion to use a copper sleeve with a 1"OD to replace it. JB Weld liberally applied inside the plastic tube, then slip the copper sleeve inside, and clean up any extra JB - should work just fine. Had to do this to the filler tube too. Cleaned the inside of tank with some water/vinegar/stones - shaking it plenty to try getting the stains out - only worked a little, so have to live with it. The rusty gunk that came out on the level sensor was gross, so everything was cleaned with a fine brush and Simple Green Max. Not sure how the level sensor thing works as I couldn't make any actuator move, only the little float cap on top. Cleaned the electrical contacts, and checked the rubber gasket to make sure it was still whole, then reassembled the tank. I used Grote Ultra-Seal corrosion preventative sealant to protect the contacts - it is like a light grease. Checked the pump operates by jumping it on the battery - good to go! Moved on to the small washer pumps, and both needed cleaning - one was jammed from corrosion, so they got stripped and cleaned thoroughly, then tested fine after. Also got the bumper cleaned, clear coated, and installed, then installed the grill after it was cleaned and painted too. The front end is coming back together!
Found out what people have talked about when it comes to rust in the washer reservoir tank - NASTY! Porsche missed a technical detail on that one! I managed to chip out the rusty sleeve, and followed someone's suggestion to use a copper sleeve with a 1"OD to replace it. JB Weld liberally applied inside the plastic tube, then slip the copper sleeve inside, and clean up any extra JB - should work just fine. Had to do this to the filler tube too. Cleaned the inside of tank with some water/vinegar/stones - shaking it plenty to try getting the stains out - only worked a little, so have to live with it. The rusty gunk that came out on the level sensor was gross, so everything was cleaned with a fine brush and Simple Green Max. Not sure how the level sensor thing works as I couldn't make any actuator move, only the little float cap on top. Cleaned the electrical contacts, and checked the rubber gasket to make sure it was still whole, then reassembled the tank. I used Grote Ultra-Seal corrosion preventative sealant to protect the contacts - it is like a light grease. Checked the pump operates by jumping it on the battery - good to go! Moved on to the small washer pumps, and both needed cleaning - one was jammed from corrosion, so they got stripped and cleaned thoroughly, then tested fine after. Also got the bumper cleaned, clear coated, and installed, then installed the grill after it was cleaned and painted too. The front end is coming back together!
05-23-2011, 11:56 PM
#96
Rennlist Member
Lookin' great, all around...
05-24-2011, 05:41 AM
#97
Three Wheelin'
Join Date: Sep 2003
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Good luck getting the windsheild washer pump to work reliably. I spent more time trying to make the washer work than any other task on the car. I finally replaced it with a third party pump from rock auto. Some upgrades car worth doing.
Zep makes a purple floor cleaner that will freshen up the plastic tanks and take the yellow color away.
Zep makes a purple floor cleaner that will freshen up the plastic tanks and take the yellow color away.
05-30-2011, 11:39 PM
#99
Pro
Thread Starter
Finished a bunch of small details around the nose, trying to get all the parts I can back on the car before tearing down the engine. Stripped and cleaned all the front lights, and found a few issues with the previous repair work such as lens gasket missing and wrong hardware used to assemble a light. Seemingly minor things, but they bug me, so looking for a few tiny parts to get things back up to snuff.
I finally tried to tighten the brake hardline fitting hidden behind the master cylinder, and found no access - just can't be done with the tools I have, so bit the bullet and VERY carefully removed the brake fluid reservoir from the grommets, luckily no breakage! Tightened the fitting, had new grommets waiting, so popped those in, and all is well.
I finally tried to tighten the brake hardline fitting hidden behind the master cylinder, and found no access - just can't be done with the tools I have, so bit the bullet and VERY carefully removed the brake fluid reservoir from the grommets, luckily no breakage! Tightened the fitting, had new grommets waiting, so popped those in, and all is well.
05-31-2011, 12:01 AM
#101
Drifting
Al,
I'm late to the game on your thread here. Just happened up on it tonight.... WOW! Its looking better than great. Keep the pics coming. Great color too.
I'm late to the game on your thread here. Just happened up on it tonight.... WOW! Its looking better than great. Keep the pics coming. Great color too.
05-31-2011, 04:51 AM
#102
Three Wheelin'
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What I notcied on the Euro model driving light set up is two driving lights. The US model has one driving light and one parking light. Some federalization programs put a light bulb into one of the driving lights.
One my US 78 I am elimining the parking light for two driving lights - one clear and one yellow for the fog we get around here. To get the parking like I am putting in a dual filiment in the directional light. This is how things are set up on the S4.
One my US 78 I am elimining the parking light for two driving lights - one clear and one yellow for the fog we get around here. To get the parking like I am putting in a dual filiment in the directional light. This is how things are set up on the S4.
05-31-2011, 09:24 AM
#105
Pro
Thread Starter
Jim, I'll send you an email - Thanks!
Dan, my inboard light is a single bulb, and outboard has 2 bulbs, one of which had the federalization wiring tapped into for the ugly side markers added on. All the solid aluminum parts have been blasted clean then clearcoated.
Thanks Dean! Your project has been amazing!
Colin, I'm considering moving the plumbing for the front headlight nozzles to the windshield for more volume. Thanks for the S4 tank suggestion.
Dan, my inboard light is a single bulb, and outboard has 2 bulbs, one of which had the federalization wiring tapped into for the ugly side markers added on. All the solid aluminum parts have been blasted clean then clearcoated.
Thanks Dean! Your project has been amazing!
Colin, I'm considering moving the plumbing for the front headlight nozzles to the windshield for more volume. Thanks for the S4 tank suggestion.