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964 C4 light refurb

Old 10-17-2015, 06:23 AM
  #16  
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So this is what the 'light' refurb looks like now

Replace control arm bushes
Replace rear spring plates
Replace all spark plugs
Replace oil
Replace distributor caps and rotors
Replace alternator fan
Replace Rear Main seal
Place sleeve on nose bearing
Replace rear reflector
Replace lenses on rear indicators
Replace side indicator plastics
Replace rear licence light fittings
Repair cracks in rear bumper, shark fin, and side sill plastics
Replace CV boot and regrease CV joint
Replace two hard clutch lines
Fit speed bleeders to clutch slave cylinder and diff locks
Replace all body seals except window seals
Replace felt window scrapers
Replace all black door and window trim
Replace front portion of carpet
Repair cracks in door pocket screw areas
Replace inner door handles
Replace door sill covers and carpet trim trip
Replace Porsche bonnet emblem
Adjust valve clearance
Replace fuel filter
Re-anodise Gemballa aluminium pedals
Refurb rear shocks
Replace gearbox diff clutch pack
Replace synchros in 2nd, 3rd and 4th gears
Replace third gear set
Replace 3rd/4th gear guide sleeve
Replace dog gear on 4th gear set
Fit reinforcement kits to both door checks
Repair damage from hyper extended driver door
Repair bumps from bonnet closing on over filled frunk
Replace crank ref sensor
Replace or refurb upper valve covers
Gut catalytic converter
Powder coat engine tin
Powder coat intake runners
Replace oil breather pipe
Fit exhaust cut out
Fit PDAS light
Layup carbon fibre over front splitter
Replace distributor belt
New front frunk struts
Replace rear decals
Replace engine decals
Plus replace hot air hoses in engine.
Respray car in L908 Grand Prix Whiten
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Old 10-18-2015, 01:52 AM
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Car on its way to the painter
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Old 10-24-2015, 03:26 PM
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Time to change the rear indicator lens. Replacement bought from Design 911.
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Old 10-24-2015, 03:29 PM
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Changed the rotors and distributor caps. More a while you are in there job than a necessity. Plenty of labelling to reduce the likelihood of getting a couple of wires crossed.
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Old 10-24-2015, 03:34 PM
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First piece of carpet replacement. This piece is next to the throttle pedal. I was careful to get the correct nap orientation as otherwise the feet will rough it up. Ados F2 contact adhesive. It was an easy job.
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Old 10-24-2015, 03:36 PM
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Somethings are just easier to do with the engine out, replacing the oil breather hose was an easy choice as it was hardened and apparently prone to leak.
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Old 10-24-2015, 03:41 PM
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In two minds about the emblem. Simple fact is that the new ones are shinier and the stallion shape has changed. I may refit the old one.
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Old 10-24-2015, 03:48 PM
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Meanwhile the gearbox rebuild is progressing. A slight hiccup when the dog gear on 4th was found to be skewed. Nowadays it can be sourced separately. Sorry, not sure how they fixed it to the gear, before you ask.
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Old 10-24-2015, 03:53 PM
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The parts flow continues. Some expensive door and window trim. Not necessary, but I really want this car to pop and these will set the new GPW paint off.

Btw the reason I have a VW catalogue is the my body guy recognised the window felt scraper as a VW part, albeit shorter, than used in his Ghia. A huge saving buying in that part.

Next up is fitting the nose bearing collar. A 3:1 torque multiplier will help getting that bolt off.
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Old 10-25-2015, 04:29 AM
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Carpet shows real difference in daylight. I cut out a strip of carpet which fits the driver sill area and will go to an upholsterer. I'm hoping we can reuse the vinyl insert.
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Old 10-25-2015, 04:33 AM
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Both door pockets were cracked at the screw fixing point. A simple fix with epoxy, mat and plastic cards
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Old 10-25-2015, 04:39 AM
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I had new door handles which were at one stage destined for my now sold Turbo 3.6. It's relatively easy to fit them if you remove the circlip and twist the holder far enough to remove the handle.
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Old 10-25-2015, 04:45 AM
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Moving on to the alternator. Carefully noting the shim positions. The fan has a damaged blade and cracked hub but I'm not sure it's past its best. I do have a new one if removal shows more corrosion in behind. I did replace the air duct.
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Old 10-26-2015, 04:10 PM
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Banal but necessary, carpet cleaning. The 25 year old Sliverknit is holding up well. Psychologically, cleaning is a major event as opposed to replacing, as it acknowledges that this is a light refurb, not a full on restoration.
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Old 10-26-2015, 07:54 PM
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Rennline engine carrier reinforcement kit has arrived.
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