924Board.org

[paul_mck]

Hi all just signed up and wanted to say hi.

Myself and a friend bought a car for the Rusty Nuts rally (A charity 3 day drive around the north of Ireland). We bought it for 500pounds as a non runner, got it running, some basic jobs for MOT test, and then hooned it around N.Ireland for 3 days as part of the Rally. This included 3 track sessions at a local track which was good fun.

So after the rally we weren't sure what to do with it. Ive been after a project for ages so cut my friend loose and took full ownership.

Some pics as we got it:





Doesnt look too bad but some serious issues:

- it didnt run (DME relay borked)
- both sills needed patching
- speedo didnt work
- most electrical stuff didnt work (sunroof/boot release/heater etc). Most fuses were corroded so ok once replaced.
- radio borked, wiring a mess
- rear number plate lights didnt work
- both front seats have tears in the fabric
- bad dent in rear panel
- front and rear bumpers a mess
- exhaust blowing out
- rear lid motor wiring and mechanism a mess







So we sorted most that, as well as wheel bearing, PS belt, quick oil service, and it was good to go. Years ticket on it and rally time!

[paul_mck]

First up the car was made to run. DME relay sorted it. Then the sills were looked at. Couple of panels welded in and skimmed over then painted black.

[URL='http://s17.photobucket.com/user/paulmckernon/media/924S/rally/00464675-C6A4-41B7-B833-0919049562F6_zps97sgdgre.jpg.html'][/URL]

[URL='http://s17.photobucket.com/user/paulmckernon/media/924S/rally/79609609-7A6C-4512-8DE1-5A788214691E_zpsvafw8fqi.jpg.html'][/URL]

[URL='http://s17.photobucket.com/user/paulmckernon/media/924S/rally/C7B3EC92-90FB-4DB6-9F9B-B0F02FF48D80_zpsztlmszys.jpg.html'][/URL]

Speedo cable replaced, wheel bearing replaced and it was good to go.

[paul_mck]

So 450 odd miles around NI and only one problem, refused to start in Aughnacloy 6 miles from the end of day 1. Quick (and I do mean quick) tow to the finish and traced problem to another duff fuse or bad connection for DME relay. Not sure which sorted it but been 100% since.

Some larking on the beach:



Amazingly didnt spend too much time in petrol stations



Quick nip round nutts:

[paul_mck]

So at this point it got parked up at mine and ignored for a week. Then I took it over.

First off strip off all the stickers and liquid wrap. I really should have bought my friend out AFTER letting him help me do this as it was a F**KING NIGHTMARE. Took over a week to get it all off. We didnt put the wrap on thick enough (was a quick lash for the rally) so had to pick it off in little bits. many blisters later it was white again.



So first thing I done was to figure out what was rusty. Stripped the whole front off:



Actually pretty good under there:





Used a dose of Krust on anywhere that had surface rust.

The front bumper (fibreglass) had a couple of chunks out of it, so out came the pot of pon and the bumper got a fill and lick of paint. Plus some new pressed plates:









Some satin black on some parts to tidy them up.

[paul_mck]

Next up was the rear. Had that ugly dent in the rear panel (at the S in porsche)



filled it with pon, not the handiest shape to rework

Built it up over about 4 goes











Still needs another go but will do rightly then.

Also took off the rear mudflaps to see what state the car was in under them. Not too pretty but no holes. Grinder took the surface crap off then rust treated, skim of pon and coat of primer.









Will bond the mudflaps back on after as the mounting lugs are shot.

[paul_mck]

And how it sits now. Will get those rear aches and rear panel painted next weekend likely. Someone bonded in the drivers side rear light so I cant get it out!



Also have ordered new side trims and PORSCHE decals for the doors and rear panel:

[IMG]http://i.ebayimg.com/00/s/ODAwWDE1NjE=/z/DWIAAOxyHntSV7mq/$(KGrHqN,!jcFELPZTbc8BSV7mqJ6Q!~~60_57.JPG[/IMG]

[paul_mck]

few things done this week. Replaced the bonnet struts so now I can have the bonnet open without propping it up with a jack handle (y)



Also replaced the crappy porsche steering wheel with a momo item. Waiting on a horn push for it hence the hole.



And lastly fitted a "racing chip" for a bit more oomph. Fitted it tonight and in fairness it defo feels sharper! Every little helps when you only have 160bhp. Ill pick up an induction kit for it over winter and likely get a stainless exhaust made in the new year sometime. Just pipe it from the manifold down to a single backbox.

[paul_mck]

Some 17" boxter wheels then happened. 7F 8.5R

(A)

[paul_mck]

bit of work yesterday - painted the front left and both rear arches due to surface rust. also finished the rear after I got the rear lights out. I was cursing some twat for bonding them in then realised thats normal lol. So apologies whoever you are

Never a good idea doing this outside but got there in the end. Still have to flatten the paint and hope it blends ok with the original paint but sure will see how that goes







Then the rain started so had to fashion some tents asap!!



rear prepped



done



And tucked away

[paul_mck]

Slow going today. Handful of sheared bolts and a couple cut off. 26 years since they were last off most likely. Axle still in, box still in but nearly everything stripped inc exhaust shocks driveshafts etc.

[paul_mck]

Beam out, box out.

next up fuel tank out and clean up the boot floor with the wire wheel, then treat it.

[Grenadiers]

Wow, amazing job! And, can't believe how rusty the old girl is. My '88 'Texas' 924S is not rusty at all, but two owners ago beat the crap out of the body. After redoing the mechanicals for track days, the body is left; dents and faded paint. Since I can't do bodywork, usually looks worse after I'm done, I'll probably just leave it as-is!
_________________
'83 944 Track car.
'88 924S Track car.
'89 944 Turbo
2004 Winnebago Vectra monster RV
2012 Jeep Wrangler
2014 Kia Soul
2001 Ford F350 powerstroke

[paul_mck]

you know it rains a lot in Ireland lol?

Well been slowly plugging on.

First job was to to drill out the 4 arb bolts that snapped off in the beam mounts. Broke 2 stud extractors so just drilled and retapped.



Then the two bolts that hold the beam endplate on. Two snapped at the head as the bolt shafts were seized into the alloy endplate. Used the grinder to make 2 flats and wrung it out with an adjustable spanner.



Next up we have the exhaust heat shield. 2 bolts snapped so drilled out then cleaned up the part. Its now painted in zinc primer.







Now that's done next job is to pull the 4 main bushes at the back. 2 in the trailing arms and 2 in the endplates. Home made puller wheeked them out nicely.



The trailing arm bushes had a nice surprise once removed there was a metal sleeve pressed in.



Grinder and hacksaw sorted those.







Cleaned up and new poly bush inserted.



The beam bushes seem to be incorrect though they aren't long enough. So likely need to be sent back and swapped for correct ones.

[paul_mck]

Also had some time this morning at the car so got a couple of jobs done.

First up fit the pioneer speakers I got. More to get the box out of the road lol.



Next up was the main event. Fuel tank removal. Not the handiest job I have to admit.

Disconnect the filler pipe and various breather pipes.



Was sure the strap mounting bolts were going to snap but held and got them undone.



And leaves a big hole.



Looking grotty. 99% superficial I reckon. Drill and wire brush be flat out.





And the man himself. Soon to be tested and restored if lucky.



Removed the fuel pump and filter so I can clean up the mounts. Looks worse than it is lol. Will also replace rubber hoses might as well.

[paul_mck]

beam in zinc primer. probably going to paint it in gunmetal grey



heatshield in zinc primer. will be painted in black BBQ paint for heat resistance.