Project Lazarus

[husker boxster]

So it's been a while. Caught a nasty cold at Thanksgiving that's slowed me down significantly. I thanked the guy in KC for offering to buy my shark, but I felt like I'd be letting $$$ go if I sold it before it ran. Plus I want to see this thru (and I'm starting to like her).

I put the new injectors in (pictured) and then topped it off with the fuel rails (not pictured).





I pulled the plugs and put a bit of Marvel Mystery Oil into each cylinder. Figured it would be wise to let them soak in it for a while before I start her.

I have a table full of fuel related parts.


Then I started removing 30 yr old fuel hoses in the engine compartment. Several are on the back side of the engine.



Here are the new replacements.

The plastic is where the MAF should be. Easier to work on the hoses with it off.

Then I turned my attn to the the gas tank. I got the cover off the fuel pump and filter and drained the gas. Didn't look too bad (the fuel in the injectors didn't look bad either).

It didn't smell bad so I tossed it in my lawn mower and mulched the leaves in my yard.

At the moment, I'm stymied by a stuck bolt. It's by the nozzle and holds the nozzle in place. I've sprayed it with aerokroil but I've run out of it and can't find any locally. Been using a WD40 penetrating oil as an alternative. The bolt has the hex insert and unfortunately it's a bit rounded (maybe due to being stuck).

I took a big chance by taking a dremel and cut a slot into the bolt.


I placed a rag into the fuel nozzle and put a wet rag over the area. There were a few sparks when I cut it. I had a bucket of water and a fire extinguisher close by. And I put my driving helmet on for fire protection. Luckily no explosions. However, the bolt is still stuck. I've been spraying it for several days. And I have one of those impact tools that has a screwdriver bit in it and when you strike it with a hammer, it twists counter-clockwise. But to no avail. The screwdriver bit is smaller than the slot so it's not getting max force with a strike. May have to think of a Plan B or C. Heat is not an option.

That's my update. If I can get that bolt off and the tank out, I can insert the new strainer, filter, and hoses. Then I'll be ready to attempt a start.

[husker boxster]

Success!!! The gas tank is out.



Sat at our monthly Porsche breakfast, someone said they had an impact wrench I could borrow. So I stopped by his house. Unfortunately, it was the same kind of tool I had - you put a bit in it and strike it with a hammer and it twists. However, he had a larger straight screwdriver bit than mine, so maybe it would provide more torque on the bolt. While it fit the slot in the bolt better, it didn't budge it even when striking it with a BFH (I was avoiding using a BFH in case I missed or the face slipped on the wrench). Dang!

But I got an idea. I built a concoction of of bits that would end up on the end of my mom's impact wrench (well it's really my dad's but he's been gone for 33 yrs). I put the screwdriver bit into a 5/16 socket, added a 1/4 to 3/8 socket, then a 3/8 extension, and finally a 3/8 to 1/2 drive socket. Stuck it on the impact wrench, put it on the bolt, and let her rip. 4 sec later it was spun off and free! Hallelujah!!!

Took a little more work to get the tank completely out, but it's on the ground.

[rexcramer]

Well done sir. I'm a bit surprised you didn't shear the 3/8 - 1/4 adapter.

[husker boxster]

Fuel Strainer Part I

Been working on replacing the fuel strainer in the btm of the tank. It screws into a metal collar that's stuck inside the plastic tank. In theory, you unscrew the old strainer and screw the new one in. Good theory but not reality when the strainer doesn't break loose from the collar. Used the impact wrench but the collar, not the strainer, just spun in the neck. Got the strainer / collar combo out. Here they are, old strainer + collar on right, new strainer on left:



I soaked the threads inside the collar and tried my darnedest to remove the collar from the old strainer, esp without tearing up the teeth on the collar. No luck. Put a thread out on the RL 928 forum and got a resp that said throw the collar away and buy Roger's replacement. It looked promising, so I purchased it.




To install the new collar, you have to fish it on a wire that starts at the top of the tank in the sending unit hole, which isn't big enough to stick my hand, let alone my arm, thru. Got the wire fished thru properly.



With some mechanical fingers, I'm able to get the collar close enough to the hole that I can get my fingers on the collar and get it lined up but not into the neck. Put some thought into it and developed a puller from a 6" carriage bolt, a 3/8, 7/16, and 3/4 flat washer. I cut a slot in the end so I could hold it in place with a screwdriver when tightening it down.




Fished the puller into the tank and grabbed it with the fingers. Put the washers on the outside and began tightening it down.



Can feel it sliding into the neck. This is good. Release the puller and check my work. The collar is in the neck but only 1/2 way.



Since I'm sitting at 8 pics and only allowed 10, the rest of my story in the next post.

[husker boxster]

Part II of Fuel Strainer post

Unfortunately, the collar was too low to catch the threads of the strainer. Fished the puller back in and ran it a bit farther and then backed it off. Collar stayed in same place. Looks like the inner tank baffle is holding the collar at it's current place and won't let it go further. Hmmm...

So I thought about it and decided to try a smaller version of my puller, so I could see what was going on.



I was correct - the puller would move the collar up the hole but it would go back down when released. Put some more thought into the situation and decided to try a bead of super glue higher up in the hole, then use the small puller to position the collar high enough that the glue catches the collar. Left it sit overnight with the puller in place. This morning I removed the puller and the collar was holding in a higher position.



I carefully placed the strainer in the hole and lightly started to screw it in. It caught! I was able to tighten it down. Success!



Guess the acid test is when it's back in the car and I add some fuel. I should mention that the 6" bolt was a tad long. Had issues with getting it fished out. I cut it down to 5", which was better, but 4.5" would be optimal.

Next up is putting the tank back in and attaching the fuel pump and new fuel filter. Waiting for a connecting pipe between the pump and filter. Supposed to arrive on Mon (fingers crossed). May not be too long before a test start.