I promised I'd post it. My 924 project (pic heavy)
PLEASE NOTE : timelines are going to be way off, this is off of another forum I originally posted it at. Hope you enjoy. (mods, i edited out and/or censored my language in it, no worries ;) )
___________________
Well... figured I may as well start off with some before and after and where the car went at least. Since so far this thread lacks substance. Here's some content from the worklogs when i first got it.
The condition it came in when we first picked it up was pretty narly. The rotors were rusted shut, brakes rusted shut in the back, ebrake stuck, no start on engine, interior was torn to bits, and it was infested with black widows. (yeah, i bug bombed it, unfortunately, and god that stuff stinks)
Nasty.
*gag*
gotta love the moldy back seat.
12-11-2010, 08:35 PM
CorsePerVita
Re: I promised I'd post it. My 924 project (pic heavy)
So at first I was going to leave the seats. But after wanting to actually strip the interior and go full track car with a few cosmetics, I decided no on it. But here's the seat resto anyway. Before and after...
After
doors before
doors after
ripping apart the console and tearing into the wiring
the lovely damage.
12-11-2010, 08:36 PM
CorsePerVita
Re: I promised I'd post it. My 924 project (pic heavy)
The dreaded engine bay......
Who the F*** would even try, right?
12-11-2010, 08:45 PM
CorsePerVita
Re: I promised I'd post it. My 924 project (pic heavy)
tasty fuel lines.
getting into the floorpan...
Assessing damage
Condition of everything else....
schweeeeeet
Scared yet?
12-11-2010, 08:46 PM
CorsePerVita
Re: I promised I'd post it. My 924 project (pic heavy)
Rip that **** out of there!
Clean up the throttle body...
More dis-assembly....
Fixing the motor for the lights
Finding some original OEM goodies.
12-11-2010, 08:46 PM
CorsePerVita
Re: I promised I'd post it. My 924 project (pic heavy)
The complete transformation of the throttle body after a full clean, glassbead, a little polishing with a dremel, and repaint. (has since been pulled and polished more and also lubed since then too)
12-11-2010, 08:47 PM
CorsePerVita
Re: I promised I'd post it. My 924 project (pic heavy)
Finally...
Airbrush time
Pics of the engine bay progress...
Then
Little later
12-11-2010, 08:48 PM
CorsePerVita
Re: I promised I'd post it. My 924 project (pic heavy)
The first start.
Our first limp on the road to a gas station for the first time in 10 years.
Fixing the **** drum brakes.
Gee wonder why they were stuck.
Working on weight reduction. Remember before...
Ah fun times.
Closer....
And closer...
Get that****t out of there.
Ugh.
There we go...
While I was at it... old cable was shot. Wanted to open hood in the morning.....
Old one was a bit of a miss.
Sealed trunk later and a new carpet mat later... (still need to grind down the rear parts up near the hatch and seal and paint those, but the actual trunk is finished)
12-11-2010, 08:48 PM
CorsePerVita
Re: I promised I'd post it. My 924 project (pic heavy)
A newer video of it running a lot more smoothly
Last video i had uploaded after fixing a ton of vacuum leaks. Meant to say "most are vacuum line routing" not leaks on the working kinks out, but anyway....
You'll also notice a lot more parts replaced. Lots of less rust in the engine bay in the last vid.
The engine will be rebuilt over the winter if all goes as planned, since the car was vandalized, i have little choice anyway.
And the day i took them out for fun...
PS: This is more of a cliffnotes sort of snapshot of it, since I actually have over 30 pages of worklogs on my website about it.... lots of pics though on my photobucket with it.... http://s225.photobucket.com/albums/d...hoshi/porsche/
12-11-2010, 08:49 PM
CorsePerVita
Re: I promised I'd post it. My 924 project (pic heavy)
got a parts car.
The good news - got the engine running and turning over today. LOTS of parts on it are in insane condition. Before it was parked the engine apparently had been replaced on almost all of the CIS parts. Almost all of them are in immaculate condition. The fuel system was my biggest concern and I am IMPRESSED.
Tranny is great, torque tube is in awesome shape and the engine is better than I could expect. Mind you the rest looks like pure ass.... this would have cost the same as my parts budget for a while, so I won't complain since it was FREE!
My this car rest in pieces when I'm done parting it out. I feel bad that it lived such a great life to come to such an end, but this car would take a small army to get it back on the road.... it will serve a great cause :)
Stay tuned.....
12-11-2010, 08:49 PM
CorsePerVita
Re: I promised I'd post it. My 924 project (pic heavy)
Got bored today so i started working on the new gauges which were in wayyyy better shape. Was going to get to work on stripping some stuff out and getting to work on the dash.
However, I can't find the strips of carbon fiber I had for it.... so i worked on the gauges and getting them back in shape.
I salvaged the extra console i have and basically stripped it of the switches, gauges, etc, which I am going to reuse on a small, carbon fiber layered display once i'm finished. Because i'm finicky and picky, i decided to take them apart, clean them up, etc.... tested them as well. Obviously there's no point in using gauges if they don't work, right? And that milky look you get when gauges are 20+ years old? Annoying, right?
Here's the console itself.
Pulling the gauges.
Switches (tested each one, work great)
Process of testing and fixing gauges. First off... These are in WAY better shape than my last ones. They just need cleaned. On these particular gauges Porsche uses tools to essentially put a small metal cover over a rubber gasket that seals the back onto them. It's a delicate process to try and take the cover off.... not break the glass... and put it back on properly...
Cleaning up the exterior metal.
The back and contacts.
That milky look i was talking about.
First, test it and make sure it even reads voltage.
Sweet.
Taking the back off to clean the contacts and make sure 100% we are getting the best POSSIBLE connection at all times. Remember these contacts are from 1977!
Sand and clean these down, ensure the plugs are done well.
Looks bent, but corrects when putting back on. Delicate... remember...
Gasket.
If the inside is in good shape it'll be nice and black, look clean and solid. Remove any contaminants inside the gauges...
Make sure you are happy with the glass before you put it back in. I gently blow on mine to remove any dust, and then use something soft to wipe it off. Put it back in the gauges and if there's dust, blow it off and do it again. I touch it with a napkin so my fingerprints don't get in it.
Sweet. There's glass in there?
And done.
I also got bored and figured I'd see if the badge was also able to be fixed. Covered in some sort of awkward primer, paint, and house paint?
So i started wiping away.... something is under there.
After a lot of using my own little tools and chems to get it down to where it needed....
Finally....
After a nice polish. Just needs a little hand polishing now...
Before and after. This goes on the car last. It's not finished till the badge is on it :)
12-11-2010, 08:50 PM
CorsePerVita
Re: I promised I'd post it. My 924 project (pic heavy)
Got the engine almost out today. Down to the bellhousing and unbolting it. Andy is being a badass and helping me pull it tomorrow with a cherry picker. Got an engine stand for Christmas and am going to rebuild and reseal the engine and use the opportunity to completely go through it before transplanting it. Should be a great opportunity to build my megasquirt system here pretty quick.
All that will be left is the cosmetic bullcrap, getting the suspension in, and it'll be able to be easily transformed from there. So if all goes well should have it up for autocross next season. Will just depend on progress and how things go. Worst case scenario I can always get the Ducati out on the track next year if I don't get the 924 done in time so I'm not too depressed lol.
Have pics, will wait till it's all out tomorrow before posting them.
Although i'll post this one, haha, my friend andy came over to help! So all 3 of us were basically tearing everything out of the car, didn't take long to get it down to the bellhousing.
12-11-2010, 08:50 PM
CorsePerVita
Re: I promised I'd post it. My 924 project (pic heavy)
Prepping to pull the *******.
Ugly, but not rusted, needs cleaned and runs great.
This windshield has aerodynamic A/C mods!
My buddy Kenny drinking his coffee with an elegant touch.
Cherrypicker time!
Me disconnecting the crossmember to get the engine out.
And...
YES
Finally it's home.
Now the real work can start.
12-11-2010, 08:51 PM
CorsePerVita
Re: I promised I'd post it. My 924 project (pic heavy)
Zündfolge! I love original parts.
12-11-2010, 08:51 PM
CorsePerVita
Re: I promised I'd post it. My 924 project (pic heavy)
Finishing the rear seat and floorpan.
Few more days of project time and I should have the entire floorpan and rear seat sealed and painted and finished. Sanding, prepping, stripping, sanding, prepping, stripping, repeating on all areas that need it. But at least I get to use all my new powertools. hehe.
12-11-2010, 08:51 PM
d_stilgar
Re: I promised I'd post it. My 924 project (pic heavy)
Totally sweet.
12-11-2010, 08:51 PM
CorsePerVita
Re: I promised I'd post it. My 924 project (pic heavy)
Dead smack in the middle of the rebuild. I've got all my ARP connecting parts ordered. Head gasket is here, all the seals are here.
Also bought a yard of carbon fiber so I can lighten certain areas and parts within the car to get rid of some nice weight.
Also fabricating GT lights which is about 50% done. They're being a pain in the ass, but they're coming along.
I have also got a quote directly from Crower for connecting rods and bolts. Should be ordering them here in the next coming week. Not in a huge hurry as they take 6 weeks to order anyway... pain in the ass to wait, so i guess i won't be finishing the rebuild as soon as I expected. But i want them badly, and don't feel like putting it together, running stock rods, tearing it down in 6 weeks and doing it over again. So.... I'll wait.
Also started on head work, but can't do a lot of it myself since i don't have the machinery - so i'm going to have to find a place to ship it off to as I'm ordering a big valve kit for it, new seats, etc as well that comes with the kit.
Does anyone also know of a good shop I could bring the block to for hot tanking?
The below pictures are the project car engine. The head is in far better shape than my own, but suffered a head gasket blow as well. And obviously had **** that sat. So looks like i'm going to end up honing the cylinders a fair bit.
Valve tappets are in great shape. So is the cam. Don't mind the dirt on the top, it's from taking the distributor off the engine.
This is when I went "Ugh."
Reason for the failure. If you can't see why, well... we need to have a talk.
I need to snap some pics. Just too damn lazy to care right now. But I'm down to the block, everything is in pieces
12-11-2010, 08:52 PM
CorsePerVita
Re: I promised I'd post it. My 924 project (pic heavy)
The barf looked worse than it really was. That's mostly since it sat. It cleaned up just fine.
Also ordered this :) just what I was looking for on the head work.
Hell, it even came with a coupon!
12-11-2010, 08:52 PM
CorsePerVita
Re: I promised I'd post it. My 924 project (pic heavy)
All the way down to the block. Next stop - Hot tank, hone, and machine work.
Pictures of cylinders. Not that bad. Will need honed.
Perspective from the bottom end
Crank is in very good shape.
This had me going "huh.." as it has some oddball wear. Doesn't look rotational since it goes back and forth diagonally, perhaps factory? Odd.
Yep. Ick.
Another of the odd wear.
I think the pistons could be cleaned up and reused but I think I may wanna just get new ones since I'm already getting new rods.
12-11-2010, 08:52 PM
CorsePerVita
Re: I promised I'd post it. My 924 project (pic heavy)
w00t.
12-11-2010, 08:53 PM
CorsePerVita
Re: I promised I'd post it. My 924 project (pic heavy)
Today I got the block hot-tanked. Got it back home, went after it with grinders, wire wheels, sandbits, you name it. Wiped it down in lacquer thinner to get all the impurities out and painted it. Still just doing one side at a time, but I finally decided my color combination I want for the car, I'm painting the engine to match :)
Here's what I started with.
Hot tank
More prep
And more prep
I didn't get any pictures of the total prep, was too excited. But here's one side finished.
Lots of wire wheeling, grinding, more grinding, more wire wheeling, and even pulled out the hand grinder. So mix of dremel, hand sanding and a grinder. Lots of lacquer thinner to get the rusty dust off and that's the end result.
Gonna go finish the rest here in a bit but am way tired, long day.
12-11-2010, 08:53 PM
CorsePerVita
Re: I promised I'd post it. My 924 project (pic heavy)
Here is today's post of the interior stripping. I have not shared a lot of these photos since I wanted to post them when I was close to done since it's pointless to go "HEY LOOK! RUST AND GROUND DOWN METAL!"
Since I like before and after photos.
Yay, so much fun.
Chisels, screwdrivers, hammer and armstrong.
These last 3 are the most recent.
As you can see if you look close, driver side still needs a bit more. And it's dirty as hell in there so it's easy to see all the dusty **** flying around thanks to me grinding in the car. But you get the idea.
12-11-2010, 08:54 PM
CorsePerVita
Re: I promised I'd post it. My 924 project (pic heavy)
As of today there is no more carpet/material/lining/foam/trim in the car. It's all gone now. I have dremeled/sanded/grinded/wheeled away almost all the cancer on the inside at this point and am sealing it.
It got ****ty as hell outside so i parked it for today. But I took the rear quarters out and traced them so I can finish my lexan windows and took the pillars out so I can finally put to use the CF I bought. Going to probably buy some flat media CF so I can use it for the dash and gauges and then strip out the rest of the dash.
12-11-2010, 08:54 PM
CorsePerVita
Re: I promised I'd post it. My 924 project (pic heavy)
Well guys I got some CF parts made and finally got some more **** done on the 924. The dash is officially gone, and the CF dash will be going in it's place here very very soon. I made a pillar so I can get some gauges moved since the other side of the dash will be non-existent. Should be fun times.
The dash still needs to be trimmed, sanded and cleared and is straight rough out of the mold, but you get the idea.
And here is the pillar
12-11-2010, 08:54 PM
CorsePerVita
Re: I promised I'd post it. My 924 project (pic heavy)
I like. Yes.
Still need to trim off a bit more, cut out the switch holes and finally sand and clear... but it's finally taking shape. Very proud of myself, my first big CF piece. Yes, it's ugly, yes, I realize that it looks horrible. But it's functional and does exactly what I need it to do, lose weight jenny craig style.
12-11-2010, 08:55 PM
CorsePerVita
Re: I promised I'd post it. My 924 project (pic heavy)
Got my megasquirt today off my buddy. He updated his, I went with his old one, been just sitting on the shelf waiting for me. FINALLY can start wiring the harness up.
Also, some pics of my buddy's build. He let me take some pictures today. My CIS is going away and something very similar will be in it's place. Not bad for a slow 2.0L van engine :P
12-11-2010, 08:55 PM
CorsePerVita
Re: I promised I'd post it. My 924 project (pic heavy)
Going to be picking this kit up soon as I can make it over the pass...
Quote:
Calipers, professionally rebuilt
Stainless brake lines
Steering knuckles
Fresh ATE hardware kits ($$)
PBR "Ult" ceramic pads (50%+ remaining)
Fresh rotors
Hubs and all associated hardware
Freshened backing plates
I also have a DCOE weber intake on the way so I can hook up some ITBs. Pics when they all get here.
12-11-2010, 08:55 PM
CorsePerVita
Re: I promised I'd post it. My 924 project (pic heavy)
Old dash mounts have been attached to the CF dash and fit. Fits like a glove! Still figuring out gauge placement but thus far it's going smoothly.
12-11-2010, 09:46 PM
CorsePerVita
Re: I promised I'd post it. My 924 project (pic heavy)
Quote:
Originally Posted by d_stilgar
Totally sweet.
I almost didn't see it as I was posting all my replies. Thanks! I should have a lot more progress to post this weekend, muahaha.
12-11-2010, 10:44 PM
SXRguyinMA
Re: I promised I'd post it. My 924 project (pic heavy)
nice work so far! oh and I've got the same ring as you :D is yours the one with the diamond in it or just the tungsten and carbon? I wanted it for my wedding ring, but I got it as a second ring for a first anniversary gift instead :D
12-11-2010, 10:53 PM
x88x
Re: I promised I'd post it. My 924 project (pic heavy)
Nice! I always love seeing old cars being refurbished. :D
12-11-2010, 11:03 PM
CorsePerVita
Re: I promised I'd post it. My 924 project (pic heavy)
Quote:
Originally Posted by SXRguyinMA
nice work so far! oh and I've got the same ring as you :D is yours the one with the diamond in it or just the tungsten and carbon? I wanted it for my wedding ring, but I got it as a second ring for a first anniversary gift instead :D
Tungsten carbide with carbon fiber in the middle. Pretty darn sturdy thus far.
12-12-2010, 03:23 PM
SXRguyinMA
Re: I promised I'd post it. My 924 project (pic heavy)
I've got the version with the single diamond in it, and the only issue I have is the resin over the carbon gets scratched easliy
12-12-2010, 04:31 PM
altec
Re: I promised I'd post it. My 924 project (pic heavy)
Heck of a project you got going. I've worked on worse, but not by much!
+Rep :)
Keep us updated!
12-13-2010, 12:58 AM
d_stilgar
Re: I promised I'd post it. My 924 project (pic heavy)
Quote:
Originally Posted by CorsePerVita
I almost didn't see it as I was posting all my replies. Thanks! I should have a lot more progress to post this weekend, muahaha.
Yeah, I posted the comment and there was already another page or two of posts.
12-13-2010, 08:57 AM
NightrainSrt4
Re: I promised I'd post it. My 924 project (pic heavy)
Sweet rebuild. I can't wait till we've got enough to move out of this dinky one-bedroom apartment and into a place I can have a garage. Have to finish my degree and whatnot first *grumble grumble*.
12-13-2010, 12:58 PM
Indybird
Re: I promised I'd post it. My 924 project (pic heavy)
Awesome rebuild! I've always been a huge 924 and 944 fan, so I can't wait to see this done!
-Nick
12-13-2010, 01:51 PM
CorsePerVita
Re: I promised I'd post it. My 924 project (pic heavy)
Thanks for the support guys. I sent off the plans for the custom intake manifold I'm getting built and bought some ITBs yesterday. Waiting for them to confirm the measurements are right and send it off to get CNC'd.
Here's the sketch of what my buddy put up in CAD:
And here's the ITBs I just bought.
Has the TPS, harness, rail and everything I need on them to hook up to my megasquirt. I am ecstatic. Still need to send in the head for head work and valve work etc. http://cgi.ebay.com/ebaymotors/suzuk...Q5fAccessories
12-20-2010, 05:02 PM
Snowman
Re: I promised I'd post it. My 924 project (pic heavy)
Quote:
Originally Posted by CorsePerVita
Not bad for a slow 2.0L van engine :P
Watch it bub the 2.slows are some of the best german engineering since well.. the fourties haha. Now I must go console my poor little 8 valve you hurt her feelings.
12-21-2010, 12:20 AM
CorsePerVita
Re: I promised I'd post it. My 924 project (pic heavy)
Quote:
Originally Posted by Snowman
Watch it bub the 2.slows are some of the best german engineering since well.. the fourties haha. Now I must go console my poor little 8 valve you hurt her feelings.
I know, just kidding :) If I didn't like it I wouldn't be putting money into it! haha. Good stuff though! It's loud and noisy and vibrates like crazy but god it's so much easier to work on than my 944 engine.