924Board.org

[hbsoftware]

Hi
i am from Europe, from a small and sunny country in the west of europe (Portugal)
I own a 1977 924 n/a 125hp
I travel on it every weekend and i go with it on vacation always.
It is a black car with cream letaher interior and brown dashboard
Since i bought it i rebuit the gearbox with new gears as needed and some new synchros that were broken, and i bought it a new fuel pump.the old one clogged because of a badly corroded tank cap. i also bought a new tank cap and the last original blank key with the porsche logo from Porsche iberia.

I intend to maintain my car fully running and original, so no radical modifications in my car except for the gearbox wich is a 5 speed unit from a later model .

Here go some pics of the beauty and i intend to show you a small engine repair (cylinder head gasket failure) that i am performing and restoration of some enginecomponents.

p.s. sorry for my not so good English



here racing on the kart track










as you can see there are thing in the engine bay that were invented by the previous owner like the windshield reservoir and some water tubes...but i am sorting it all out with new original parts or restored used parts like you will see

[CorsePerVita]

Welcome to the forums, nice ride!
Not bad at all, super clean!

_________________
- 1977 Porsche 924 2.0 N/A (Trackday Project)
- 1979 Porsche 924 2.0 N/A (The other daily)
- 1980 Porsche 931 (Daily)
- 1987 Lamborghini Jalpa
- 1999 Ducati 900SS

[hbsoftware]

Thank you!

here is a pic of some of the injector piping. the old ones were too badly worn and bad looking and i had them custom made using the old banjos and fittings but with new braided tube.

porsche original tubes were about 50eur each, custom tubes were 10eur each






now i am excited to finish the head repair so i can fit two special parts that i sourced here in portugal.... a pair of beautifull yellow headlights (the square ones, aside of the blinkers) these yellow lights typically fitted the French models. and a speedometer and rev counter, etc with green lettering that also fitted some 924 models

[hbsoftware]

head already skimmed...
camshaft was squared on number 4 cylinder area so i ordered a camshaft from germay, it arrived and it is as new.also sourced 3 cam buckets because mine were pitted. And a new plastic elbow for the cam oiling tube.



new bosch injector because i have a leaking injector number 2 cylinder had quite a bit of gasoline inside when i took the head off.




original windshield wiper reservoir (was hard to find)




engine mount was disassembled painted and drain holes were drilled in the rubber.before fitting i will soak it with grease


brand new exhaust manifold protection plate

hope you all like the goodies

[Joes924Racer]

Yea your going to like the outcome. Cheers.
_________________
1979 porsche 924 Na
1980 porsche Turbo 931GT Replica
Have u ever driven a turbo.

[ditch68]

Great car, it looks wonderful! Don't see too many in black.

Welcome, also!

Jeff
_________________
Current:
1979 924, all stock.
1988 951 all track modded out and angry.

Past: 1986 951, 1988 924S, 1965 912 with '69 911T engine.

[curtisr]

The car looks great! And your English is maravilhoso!
_________________
World's worst welder.

[hbsoftware]

Thank you all for the comments!
and curtisr , your Portuguese is very "bom"!

here we go...a few more bits and a little closer to the final assembly... yesterday i stayed late night in the garage removing some "pirate" wiring and restoring the wiring to original spec(or trying), removing some adapted relays, duct taped wire, etc. all new connectors crimped then welded and then shrink tube on them...pics later and fingers crossed to see if it will work fine



here the new head bolts, and top coolant hose + bleed stopper and a new air filter



head gasket set including camshaft seal and injector seals


the steel water tube was corroded on the tip so i had a new tip custom made in copper and welded


here is the camshaft..i measured all the lobes to check the 52mm spec..they were all ok and round. the camshaft was glass-pearl-blasted, i dont know why they have done that, i was worried about the surface roughness specially around the seal area but it appears to be smooth at the touch... in the photo you can see my assistant checking the camshaft: Mr. gloves - the cat




here the coolant hoses and pipe already mounted, my car had nothing of this...it had some fiat and renault hoses the pipe was painted, i know it is originally zinc plated but i am im a hurry to have the car on the road...maybe next time i will have it zinc plated

[hbsoftware]

in the process of renewing the wiring i found out that the fuel pump is not supposed to work right since you turn the key to the on position..mine does work immediately and i always thougt it was normal...i also found that the plug that goes to the air flow meter is disconnected. maybe the switch is malfunctioning and they hot-wired the pump to stay always on...any thoughts?

[CorsePerVita]

Man you really got stuff done! Your car appreciates it I'm sure!
_________________
- 1977 Porsche 924 2.0 N/A (Trackday Project)
- 1979 Porsche 924 2.0 N/A (The other daily)
- 1980 Porsche 931 (Daily)
- 1987 Lamborghini Jalpa
- 1999 Ducati 900SS

[scm924s]

Nice restoration work. On the 77 the fuel pump is energised by the inlet vacuum lifting the throttle in the AFM and energising the switch on the side. Check that you have the correct fuel pump relay for this model, it could also be that a badly adjusted mixture control on the AFM has raised the throttle to start the pump running and the previous owner has disconnected the switch and bridged the fpr.
_________________
1984 n/a Ruby Red Metallic
1988 924S Guards red- sold
1986 924S Guards Red - sold
1984 n/a Black - sold
1980 n/a Le Mans#1 - sold
1980 n/a Le Mans#2- sold
1977 Martini - sold

[hbsoftware]

Thanks corse! i guess the car has never been so happy!I have been seeing your restoration thread a couple of days ago and although you have a lot more work to do than i, you´re doing an amazing work.

so scm924s from what i understood you are sugesting that my afm can be set up wrong, i compared my afm plate to one of a donor car and mine is a bit more raised. my plate rests in the cone area, and the donor car's plate rests below on the staright area....i did not take photos but i will do it.my car always worked fine, i had him made the CO test in a porsche specialist and it was ok.it starts well cold, a bit strugle to start hot but that is traced as a leaking injector, it runs and idles fine and fuel economy is great.form what you said my guess is that the switch inside the afm is broken and the previous owner brigded the connection somewhere... anyway i repaired the wiring on the exhaust side and as soon as i have the head in place and the car running i will focus on the rest of the "minor" issues.


here i am pre adjusting the valve gap after i installed the camshaft, still with the head off the car because i only finished the wiring today and i still have to paint and mount the starter protection plate before fitting the head to ease the acess.

i adjusted inlet to 0,20mm and exhaust to 0,45mm as says in Autodata software.
do you think i will have to readjust when it's hot or it will be fine?

[hbsoftware]

here i am making a gasket for the air flow metering unit.my gasket was broken. i am making it out of special cork for gaskets. it´s amazingly resistant and much better than rubber gaskets because it also seals well but does not stretch when overtightened.



here a pic of a connector for the starter solenoid after crimping and welding.

the wires were totally fried from the exhaust heat over the years, its amazing how it worked always fine...i put new wires but reused the old heat protective sleeve that appeared to be fine.

[hbsoftware]

Hi
PLEASE I NEED HELP FROM THE 924 GURURS

so i assembled everithing and the engine harness was in quite bad shape, the plug for the thrmo time switch was missing... i rewired everithing according to the schematics, i double checked and all was OK. the car would run but very roughly and hard to start.

remember that my fuel pump would turn on when i switch the key to ON, so i fixed that..the plug for the air flow meter contact was disconnected... now the car runs rough again and its even harder to start...so i recheck the wiring and find that at the 7 pin multiplug that goes to the injection harness, the red and black wire that is supposed to bring 12v to the termo time and the CSV has ground .. I put a multimeter between that wire and the battery+ and it reads 12v WTF??

so i cut off the wire and connect it to 12v key-switched current.now the car starts grat, runs fine, has plenty of power but if i release the throttle it stalls immediately..i hear the relay cliking several times ans it stalls because no fuel pressure...I tried to lift the plate of the AFM but i flooded the engine...so i cleaned the plugs and tried again, this time i didnt lift the plate, i disconnected the plug at the AFM contact so the pump runs when the key is on (like i t was before and working well) but the car runs like shit again....i put the plug in and the car runs fine but if i go under 2000rpm it stalls and i hear the clicking of the relay going on off on off before stalling....I'm getting desperate i spent saturday and sunday trying to troubleshoot and now i have a hard week of work and the car is not running, my nerves are killing me...


here is how i rewired:

Warm up regulator and aux air valve both connected to ground. positive side of both connected to the muliplug wire that goes to the pin 87 of the fuel pump relay. when the fuel pump activates the wur and the aav will also activate.

cold start valve connected to ground, other wire of the csv connected to the thermo time switch, other thermo time switch wire connected to the pin on the multiplug thst goes to fuel pump relay pin 50...it was supposed to bring 12v but was bringing ground so i cut it and connected to 12v switched.

remember that i have an early 77 model, it still has points type ignition and only one ballast resistor. fuel pump activates by rising the air flow meter plate.

[Fifty50Plus]

Try adjusting the fuel mixture a bit with a 3 mm allen wrench through the hole on top of the fuel distributor.
My car wouldn't start at all unless I had the throttle wide open. Turned out that it was way too lean.
_________________
1979 924 NA race car H-Prod SCCA
1982 924 NA race car - Sold
1981 924 Turbo sold
1982 924 Turbo sold
1972 911 E race car - traded for Cayenne Diesel
1975 914 1.8 Building for H-Prod SCCA