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Chronicling the restoration and rebuild of Wilbur, the Pig

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Chronicling the restoration and rebuild of Wilbur, the Pig

 
Old 03-27-2018, 03:08 AM
  #46  
Foxman
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The quest to add lightness continued. I tried to shave a few pounds off the car each day.

With the Rennline radio delete plate installed, it seemed like a good time to delete the upper center console and move a few controls to the dash. I also began carefully removing the insulation out from underneath the RS carpet. The RS carpet was one of the best features of the car, but it was installed on top of the existing stock insulation. That largely defeats the purpose of an RS carpet, which is incredibly light. The plan was to carefully pull up as much insulation as possible without damaging the carpet. But as the project progressed, I decided to toss the RS carpet altogether and leave the car bare. All was going smoothly, but rust never sleeps. I had detected some rust under the driver footwell last summer. That one footwell had already had the insulation removed. I assume the insulation was water damaged. I didn't remove the make-shift wooden floor board completely, but there was some minor surface rust visible. With the floor board now out completely, and the pedal board out as well, the surface rust on the floor board was far more extensive than I had imagined. The pedal assembly was rusting as well. Thankfully it was just surface rust, so I got to work...



Radio Deleted, Insulation coming out


Stock insulation had not been removed despite the RS carpet


The insulation and glue were easy to remove here


The weight really adds up


Original plan was to retain RS carpet after removing insulation like this


Not so easy cleaning this section up
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Old 03-27-2018, 03:17 AM
  #47  
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Mice really seem to love this spot in the back seat


Insulation pulled up here in a jiffy


Arsenal for the glue. I'm a big fan of Goo Gone, but thanks to Cobalt for recommending the Xylene!


Did they use roof tar back here?


Center console delete, really


Progress
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Old 03-27-2018, 03:37 AM
  #48  
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The brackets, and oiher bits all start to add up


Removed the door sills (1/4 lb.)


Removed the sun visors (2 3/4 lbs.)


Rust in driver side footwell


Rust on and around the pedal cluster - what a cluster-*-ck


Thankfully the gas pedal is plastic - but the hardware really rusted here



Bolts securing pedal cluster - PB Blaster worked nicely here


Pedal cluster needs to come out


But the push rod for the brake is rusted solid and isn't going anywhere


Torched the mono-ball on the push-rod, but still won't budge


There's more than one way to skin a cat. Jacked up the car, took the left front wheel off


And disconnected the other end of the brake push-rod here under the boot
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Old 03-27-2018, 03:55 AM
  #49  
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Good work. Looks like the ARB bracket might be weakened by corrosion.
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Old 03-27-2018, 04:02 AM
  #50  
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While the left wheel was off,


Pedal Cluster is out!


The rust on the bearing bracket (964 355 321 03) was extensive, but the unit was salvagable


The bearing tube ((964 423 069 00) was too far gone


Pedal Cluster refurbish in progress



The clutch felt a bit stiff - now I know why. It was also double-sprung (Note extra hole in the spring support


All the hardware and bushings are removed sand replaced with new ones



Grind off as much rust as possibe


All the pedal bits
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Old 03-27-2018, 04:06 AM
  #51  
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Originally Posted by John McM View Post
Good work. Looks like the ARB bracket might be weakened by corrosion.
Good catch John, thanks. It seems the whole car is like that. New RS sway bars and brackets are in the basement, ready to go in shortly.
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Old 03-27-2018, 04:14 AM
  #52  
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With the push-rod finally out of the car, a puller makes easy work of breaking the rod free


But that darn mono-ball is still frozen solid!


Bill Pfister at Eurotech finally cuts the darn thing off


That was a PIA


I knocked off as much rust as possible


All the major bits are sent off to be powder-coated while various new parts are ordered to refurbish the cluster
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Old 04-06-2018, 10:34 PM
  #53  
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Here's where things start to go sideways. The plan was to use a wheel wire brush and drill to remove the surface rust off the driver side floor board. Heck, I had already ordered a rattle can of paint from Touch Up Direct. Easy. But as I peaked under the rubber covering the center drain holeI, I discovered that the rust was far more extensive underneath. The rubber appears to have trapped the moisture from inside, and it was literally eating away at the car. And someone at the factory really loaded it on heavily when applying the rubber on my 964.

Armed with this realization that rubber was a breeding ground for interior rust, I began inspecting the whole car more closely. Sure enough, there was rust under all of the rubber on the floor boards. Worse, there rust on the rear seats. Heck, there's rust everywhere... The one saving grace was that I caught this in time, while it was still just surface rust. So it's grind, grind, grind the rust away.



Plan is to brush away the rust on the front floor board and do a quick touch up


Peaking under the rubber, it looks like more rust hiding underneath


Yup, surface rust under the rubber


The back seat appeared to have avoided any rust


But probing under the paint proves otherwise


Wherever there's rubber, there's rust
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Old 04-06-2018, 10:42 PM
  #54  
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Where there's rubber...



Grind


Grind


And grind some more


Kicked to the driveway so I can work on the 993 for a bit...
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Old 04-06-2018, 11:03 PM
  #55  
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labor of love depicted

nice to see u document it

so pretty from 12-15 ft,,, so many signs of age and environment down below and in the innards
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Old 04-07-2018, 06:15 AM
  #56  
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Good work mate, lucky you got to the rust before it got any worse. Man I can't wait to see the interior finished. You should just polish it lol
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Old 04-10-2018, 05:39 PM
  #57  
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The pedal cluster box and pedals look great after a fresh powder coat. I purchased new bushes and hardware and reassembled the pedal cluster. But the hole in clutch arm didnít line up properly with the kinematic lever. It seemed like the clutch tube was 4mm longer than the original tube, but itís the same part number! Hold the phone. It turns out Porsche messed up and mislabeled all of the clutch tubes now in stock in the US. Theyíre all labeled 964 423 069 00, but the part number stamped on the clutch sleeve is 965 423 069 00. Thatís the sleeve for the turbo. It looks exactly the same but for the fact itís 4mm longer.

New correct part en route now, from Germany...



Pedal assembly powder coated, all new hardware and bushes.


Clutch sleeve seems too long and hole doesnít line up.


Correct 964 part number labeled


But the part is stamped 965. Part was mislabeled
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Old 04-10-2018, 05:54 PM
  #58  
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Nice work on everything!
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Old 04-10-2018, 05:59 PM
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Originally Posted by honduh View Post
Nice work on everything!
Thank you, Sir!
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Old 04-10-2018, 08:53 PM
  #60  
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Wow... keep it up, be interested in the end product, that is if it ever ends..
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