3.2S Winter rebuild from Scotland

[Duffy3074]

Thanks for that!



I hate a photograph of a clean car!

[derfo]

Hello Duffy, I am in the uk too. 986 and Pelican are the best sites I have found so far. They are down to earth, hands on and very knowledgeable. Some of the contributers are very very knowledgeable. So you have come to a good place.
You are going to be busy like you say. Can I ask were you picked up your clocks and your 4 stork unit. On the TRW control part there is a plastic part, is it some sort of air deflector to the brakes or what.

[Duffy3074]

Have to agree with that, the technical info here (and at Pelican) is first class.

The clocks and stalk unit came from breakers in the UK who advertise on the bay of E!

Busy....yes but enjoyable.

The deflector is the air scoop that feeds onto the front brakes, meant to be a good upgrade from the standard Boxster one, it's from a GT3 I believe, got it from Suncoast in the States.

[Duffy3074]

Progress

Just finished the IMS and found a couple of interesting things.

The o-rings on both tensioners had lost their elasticity (which I only found when I tried to take them off for replacement) however looked fine on initial inspection. I'm glad I did as they are mission critical to the operation of the tensioners.

I also wished I'd known that the cam end plugs had a brass backing plate and it's only in the exact centre that you can get a pick through to get them off! This would have saved me some frustration trying to get them off!

Also fitted the 996 oil switch as part of my dash upgrade.

Lastly a couple of before and afters!

[jcb986]

Might have been cheaper to buy a new one. That's a lot of parts and time, oh well, I see you are a proud owner. Love the Fiat and Alphas that we cannot get here in the US...and I have no understanding why.

[Duffy3074]

My enjoyment comes from the rebuild and specirfying to exactly as I want it, on the cheap compared to a new car and without the depreciation or warranty/dealer concerns.

[derfo]

Originally Posted by Duffy3074

Progress

Just finished the IMS and found a couple of interesting things.

Hello again Duffy, what was the condition of the IMS, was there any play, have you had it apart? Was yours a double or single row and which kit did you use? Your making a thoroughly nice job by the way.

[Duffy3074]

The IMS felt fine, no obvious play, a little rough but with seals intact, it was however full of oil and was leaking badly.

Thanks for the comments!

It was double row and I used the pelican kit to replace it.

[recycledsixtie]

Duffy I think that you would enjoy Pelican Parts Forum as well, particularly the Boxster forum and off topic discussions
The folks there would love to see the high quality work you do as evidenced by your pics....

[Duffy3074]

Thanks for the comments, is it quite a different set that go onto Pelican rather than here?

[Joe B]

Originally Posted by Duffy3074

Thanks for the comments, is it quite a different set that go onto Pelican rather than here?

I bet many (most?) people read both forums. I do.

[recycledsixtie]

This tends to be Boxsters only here - basically three types here:
1. Folks like you who do great work themselves . There are some!
2. People like me that pay others to do great work(hopefully).
3. Lastly those that cry help I did not get a PPI on my Boxster, now makes lots of noise(or none at all), blows smoke in 5 different directions etc.

Pelican Parts forum under the Boxster section gets the same kind of situations.
Off topics forum you can bring up anything from soup to nuts.
Parf is the politics and religion forum which is not for the faint of heart.
Enjoy

[Duffy3074]

Thanks for the pointer, I'll let this run methinks!

[Duffy3074]

Before

and now some progress

60 degree thermostat, water pump and drive belt on!



IMS install completed, flywheel, clutch and gearbox back in place along with rear subframe




Quickshift installed and new gear cables fitted, along with the upgrade headers, which I port matched.

Beginning to look like a car again!

[Duffy3074]

Not updated this in a while albeit been busy!

Rear suspension going back on, I'm fitting a complete set of TRW arms and a 'ROW' MO30 kit, I should notice quite a difference.



We have a lot more corrosion here than a lot of you will see, these are the old handbrake cables that had to be chiselled off.



and the new ones



I flushed and changed the power steering fluid, the old stuff was pretty black!



I spent some time cleaning the old back box which is made by a company called Janspeed, who were very well though of across here. Between this, the sports cats and the new exhaust manifolds (headers) it sounds pretty good.





Driveshafts and rear suspenion going back on



Before....................



After!

[Duffy3074]

Rear brakes back on



No bodging!



Front suspension subframe off for cleaning



Front suspension back in situ.



and before!

[Duffy3074]

Tackling the radiators at the front



Replacement frames for the condensors/rad's due to corrosion on the old ones.



Gearbox lube kit, the original oil was very red and smelled completely different from the pukka Porsche stuff, it'll be interesting to see if there's an improvement in shifting quality.



The K and N filter went into the car 44K miles ago, it's obviously never been cleaned and was filthy.



Sorted!

[Duffy3074]

Cabin filter in the same boat!



New fuel filter, last of the new brake pipes and brake fluid.





Front end back together!



Wheels back from refurb, shiney!!!!!!

[Duffy3074]

Mechanical work is now completed with the only problem being that there was a leak from the thermostat outlet caused by a faulty hoseclip, it felt like it was torquing up to the required 15nm but was actually locked and not clamping.

Started to clean the plastic undertrays (There's a lot of them!) and put them back on.



A couple of bits of the underside being replaced



And then onto the inside!

[Duffy3074]

I've already got a 996 dash wired in and working, I ended up getting a facelift dash to go in soon



I'm going to paint the roll hoops, the dash vents and the centre console in artic silver
and I'm going to a double din Pioneer DA-100 and have got the final part of the cruise control and OBC to install (the 996 dash was a good shout as it was OBC enabled).





I'm also going to play with some alcantara covering for the door pockets, to go with the steering wheel that's already been done.

Finished by tomorrow then...............

Regards