3.2S Winter rebuild from Scotland
 

Hello!

I'm new to the forum and thought it was time I said hello and shared my winter project.

I moved from this

http://<a href="http://s1143.photobucket.com/albums/n631/Duffy3074/?action=view&amp;current=DSC_0197.jpg" target="_blank"><img src="http://i1143.photobucket.com/albums/n631/Duffy3074/DSC_0197.jpg" border="0" alt="Photobucket"></a>

to this

http://<a href="http://s1143.photobucket.com/albums/n631/Duffy3074/?action=view&amp;current=DSC_0079.jpg" target="_blank"><img src="http://i1143.photobucket.com/albums/n631/Duffy3074/DSC_0079.jpg" border="0" alt="Photobucket"></a>

to this

http://<a href="http://s1143.photobucket.com/albums/n631/Duffy3074/?action=view&amp;current=IMG_0652.jpg" target="_blank"><img src="http://i1143.photobucket.com/albums/n631/Duffy3074/IMG_0652.jpg" border="0" alt="Photobucket"></a>

in fairly short succession.

I enjoy a bit of DIY spannering and am reasonably competent with a torque wrench, ergo I usually take on something needing a bit of work. This car has 103k miles on the clock, had an extremely stiff gear-change and tired suspension along with a leaking IMS. On the plus side it's completely straight body wise, has a full history and has just had the AOS, RMS and clutch replaced within the last 400 miles and just prior to my purchase.

My plans are to strip and rebuild all of the suspension and brakes, do a pelican IMS replacement, upgrade the interior to include a 996 dash,OBC and cruise retrofit along with a Pioneer appradio2 install.

Progress so far!

Crusty brakelines at the back!

http://<a href="http://s1143.photobucket.com/albums/n631/Duffy3074/?action=view&amp;current=Porscherebuild009.jpg" target="_blank"><img src="http://i1143.photobucket.com/albums/n631/Duffy3074/Porscherebuild009.jpg" border="0" alt="Photobucket"></a>

being replaced by copper-nickel pipes covered in heatshrink

http://<a href="http://s1143.photobucket.com/albums/n631/Duffy3074/?action=view&amp;current=Porscherebuild012.jpg" target="_blank"><img src="http://i1143.photobucket.com/albums/n631/Duffy3074/Porscherebuild012.jpg" border="0" alt="Photobucket"></a>

Some bits ready to go on!

http://i1143.photobucket.com/albums/...rebuild014.jpg

http://i1143.photobucket.com/albums/...rebuild030.jpg

http://i1143.photobucket.com/albums/...rebuild025.jpg

http://i1143.photobucket.com/albums/...rebuild018.jpg

http://i1143.photobucket.com/albums/...rebuild029.jpg

Some before and afters!

http://i1143.photobucket.com/albums/...Boxster003.jpg

and now

http://i1143.photobucket.com/albums/...4/IMG_0834.jpg

and

http://i1143.photobucket.com/albums/...erstuff044.jpg

http://i1143.photobucket.com/albums/...erstuff042.jpg

Gearbox!

http://i1143.photobucket.com/albums/...erstuff048.jpg

to

http://i1143.photobucket.com/albums/...4/IMG_0829.jpg


Some future proofing and 'out with the old and in with the new'

http://i1143.photobucket.com/albums/...build016-1.jpg

http://i1143.photobucket.com/albums/...build015-1.jpg

Some bling and upgrades!

http://i1143.photobucket.com/albums/...4/DSC_0018.jpg

http://i1143.photobucket.com/albums/...erstuff050.jpg

http://i1143.photobucket.com/albums/...erstuff039.jpg

http://i1143.photobucket.com/albums/...rebuild015.jpg

Going to be busy!!!

Where did you buy the short shift kit

Okay I thought I knew cars but that first car with the lancel headlights...
what the heck is that???

Congrats. Sounds like a modern Porsche is right up your alley. I had much of that sort work done professionally, if I had your skills I might have saved quiet a bit.

Welcome Duffy, your Box looks great, from the top at least. Are those Dansk headers? You should get the GBox shift detent. Chassis parts are looking good, what are you using to clean them? :cheers:

Thanks for that.

lancel headlamps? Not heard of them before! That'll be the Fiat Coupe 20 valve turbo, used to be common in Europe but getting rare now, that photo was taken in July '12 when it was 12 years old.

The Boxster is remarkably easy to work on, easier than the Fiat by a long way, mostly due to design integrity and good material quality, no rust!!

DIY makes one of these much more affordable.

Thanks for the comments. :)

The headers are by a UK company called blueflame but probably made in the PRC!

Alloy chassis parts get wire brushed, de-greased and then cleaned with wheel cleaner.

Anything painted gets the same and then painted in satin black hammerite smooth paint.

New fasteners all round to finish things off.

welcome! bit of bugger you're at the other end of the island i would love to get stuck in with you.. no deep fried mars bars though, but a can of iron bru or two would work !

Looking good Duffy :cheers:

the best way to get to know your car is to strip it down......and put it back together :rolleyes:

Thanks guys, the spannering is the fun part for me.

I like a challenge in the garage.

That's Fiat coupe. Only in Europe tho

Love the red top! Very cool . . .

Where abouts in Scotland are you Duffy?

This must be a unique car. Impressive work, I might copy it one day. Would love to see more pictures, especially from underneath, with car on lift.

Thank you for the pictures...gotta admit your first car had me stumped as well. Will be anxious to see your final product.

Thanks for that!

I'll keep you as updated as I can.

:)

Here's another photo of the Fiat Coupe and a link to the main UK site for them.

A good crowd!

http://i1143.photobucket.com/albums/...4/DSC_0182.jpg

Fiat Coupe Forum - Forums powered by UBB.threads™

and this was my restoration on that, my aim is to do the Boxster to a similar, if not higher, standard.

Duffy's Moon Grey 20VT Plus 'refresh' - Fiat Coupe Forum

Not only beautiful work and subject matter but over the top photography skills!
Happy upcoming Robert Burns to you.

http://i1143.photobucket.com/albums/...4/DSC_0196.jpgThanks for that!

:)

I hate a photograph of a clean car!

Clocks and arms
 

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.

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.

:)

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!

http://i1143.photobucket.com/albums/...4/IMG_0845.jpg

http://i1143.photobucket.com/albums/...4/IMG_0846.jpg

http://i1143.photobucket.com/albums/...4/IMG_0841.jpg

http://i1143.photobucket.com/albums/...4/IMG_0838.jpg

http://i1143.photobucket.com/albums/...4/IMG_0842.jpg

:)

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.:cheers:

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.

:)

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.

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.

:)

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....

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.

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:):)

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

http://i1143.photobucket.com/albums/...ps8b3b2b5f.jpg

Before

and now some progress

60 degree thermostat, water pump and drive belt on!

http://i1143.photobucket.com/albums/...psa4ab5abf.jpg

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

http://i1143.photobucket.com/albums/...ps4d0f4966.jpg


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

Beginning to look like a car again!

http://i1143.photobucket.com/albums/...ps8d7ea038.jpg

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.

http://i1143.photobucket.com/albums/...ps87e0625f.jpg

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.

http://i1143.photobucket.com/albums/...ps63cc5926.jpg

and the new ones

http://i1143.photobucket.com/albums/...ps8bd38c8a.jpg

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

http://i1143.photobucket.com/albums/...ps05c6bc1e.jpg

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. :)

http://i1143.photobucket.com/albums/...ps6370f2a9.jpg

http://i1143.photobucket.com/albums/...ps53e50b73.jpg

Driveshafts and rear suspenion going back on

http://i1143.photobucket.com/albums/...ps12fe9b48.jpg

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

http://i1143.photobucket.com/albums/...ps75cf21ab.jpg

After!

http://i1143.photobucket.com/albums/...psd5489d34.jpg

Rear brakes back on

http://i1143.photobucket.com/albums/...psaf2c79ea.jpg

No bodging!

http://i1143.photobucket.com/albums/...pse24e19c2.jpg

Front suspension subframe off for cleaning

http://i1143.photobucket.com/albums/...ps5e930913.jpg

Front suspension back in situ.

http://i1143.photobucket.com/albums/...psaf5767d6.jpg

and before!

http://i1143.photobucket.com/albums/...ps8d94dd42.jpg

Tackling the radiators at the front

http://i1143.photobucket.com/albums/...pscef2268b.jpg

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

http://i1143.photobucket.com/albums/...ps7d7a5b86.jpg

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.

http://i1143.photobucket.com/albums/...ps5bf2873a.jpg

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

http://i1143.photobucket.com/albums/...ps3c368169.jpg

Sorted!

http://i1143.photobucket.com/albums/...ps994da4f6.jpg

Cabin filter in the same boat!

http://i1143.photobucket.com/albums/...ps1caa73e4.jpg

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

http://i1143.photobucket.com/albums/...psedfd1d4a.jpg

http://i1143.photobucket.com/albums/...ps1c852f59.jpg

Front end back together!

http://i1143.photobucket.com/albums/...ps5ce616d0.jpg

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

http://i1143.photobucket.com/albums/...pscecb1d9d.jpg

http://i1143.photobucket.com/albums/...ps77053104.jpg

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.

http://i1143.photobucket.com/albums/...ps39ad8fec.jpg

A couple of bits of the underside being replaced

http://i1143.photobucket.com/albums/...ps8005b780.jpg

And then onto the inside!

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

http://i1143.photobucket.com/albums/...pse60efec3.jpg

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).

http://i1143.photobucket.com/albums/...psda697e85.jpg

http://i1143.photobucket.com/albums/...psb5ff5c77.jpg

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

:)