Aaaaand again, being jelly here! I wish I would have more time and know how to do these things!

Looks really good!

Well quick update... valve lifters are back in, timing chain cases closed up, valve covers back on... its coming - slowly....
Havent had much time over the holidays but got a little bit done at least :D

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And the added touch of raising the PORSCHE script on the upper valve cover :)
Happy New Year
Heiko


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Looking good! Nice little touches to top off an ambitious series of projects.

Quick update...
Finally finished cleaning the intake tubes today, got the tranny all washed up
and finished making the new engine wiring harness... just need to wrap it
in the cloth tape so it looks original, but other than that she's good to go :)

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Very Nice work Heiko, can't wait to see the "after" pics when you're done.

I'm always blown away with the simplicity of the early cars wiring loom - compare Heiko's car with a modern day electrical system where manufacturers can use hundreds of meters of wiring just to get the engine and auxilliaries to work....

Thanks and yes I'm also looking forward to the finished pictures as well but more so to drive it when its finished... I'm so looking forward to the first ride after the rebuild :D
Steve the wiring harness for the engine is very simple... one master plug (unplug that and the whole engine is disconnected); from that plug leave 12 wires for a couple of sensors, ignition, alternator (which is driven off the back of the fan) it's really all quite simple... and so easy to work on compare to new stuff! The only downside was that the old wire when bent, basically broke in your hand, so it all needed to be replaced. The wiring which isnt near high heat sources was all ok, but all the wiring in the loom that basically sits on the engine was all brittle. We also finished the alternator/fan and fan housing, but I havent gotten around to taken pictures of that yet... A couple more weekends and the motor will be almost ready to go back in :-)

*Just for the record... still getting a lot of folks asking why I didnt paint the engine and transmission cases when i had them all apart... "The engine case is
magnesium, and I want to keep the engine case as original as possible; Also paint will act as a heat barrier, so the cases all stayed stock :D "

Well got a lot of the motor back together today (almost ready to go back in the car) just need to get the airbox and injectors done)
Hope you enjoy the pics... :) there's a few :)
Heiko
http://pcars.prophpbb.com

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WOW!! this so coool!!

I agree. Way to cool. I'm actually looking forward to doing some basic maintenance but I'd need my own garage - not a rental - or rented space to do any serious work like this.

Makes me want to expand my garage instead of remodeling the kitchen....Just dreaming, I know I would not win that option.

Heiko, Thanks for the awesome status and photo updates.

One can never have a big enough garage... get a 2 bay shop (not enough room), get a three bay shop (not enough room) - The Ideal shop would be a three or four hoist setup on one floor with a loft setup to be 'Home' :) but my wife wouldnt go for that either.
Just working on the Airbox and Injectors, new starter going in, and cleaning up and blasting and painting a few more little parts (that's what seems to take up most of the time is prepping all the little parts (but sure looks nice and original).

Thanks for the comments and I'll keep updating this thread as the project continues...

Cheers,
Heiko
Heiko's PCAR Motorsports

Once again Heiko BEAUTIFUL WORK!!!! I had to chuckle at your garage comment, it is so true.

I love these pics, it looks so (deceptively) simple when you show us all the steps. Very cool, I enjoy learning new things!

My hubby had a '75 911 (about 20 years ago) coupe with a magnesium engine, and it leaked oil everywhere, constantly. We were told that as the magnesium heats up (as it will on an air-cooled) that the magnesium expands, opening tiny gaps at the seams. And that the oil leaks would never really be solved because of the nature of the material. Is that true?

Thanks for the comments... :)
Magnesium is very susceptable to corrosion if its not treated and cleaned properly making the surface very porous (especially in damp or wet climat). The biggest downside is that the magnesium is soft which causes bolts to losen quicker etc (this was a huge issue on the cylinder studs as they all eventually began to pull themselves out of the cases and had to be repaired by installing case savers or timeserts) A lot of folks dont loctite all the nuts and bolts during reassembly either which will cause them to slowly losen off over time - The key is loctite and proper toque, and you shouldnt have any issues with leaks. We used a Gel based Anaerobic sealant which remains quite rubbery and adhers very well to the case flanges (again prepping/cleaning the flanges is also very important prior to re-assembly). Another important thing I find is during assembly.. o-rings.... always lube them slightly with an assembly lube which will cause them to slide into place easier and avoid binding or nicks in the rubber during assembly... All these things added together and you should be ok.
But in the end they will all leak at some point in time, all we can do is try to prolong the process :)
H
http://pcars.prophpbb.com/

I do remember much discussion about the bolts, now that you mention it, Heiko. I don't know why they weren't properly sealed, and yes, our environment is humid.

Well I got a few pics of the airbox going back on today but havent had much time to work on this car the last little while. Got the fuel hoses replaced, all new seals for the air intake and cleaned it up before it went back together :-)
Enjoy
Heiko

The whole airbox/intake assembly...
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The throttle body and linkage...
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The throttle body...
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Back side of the throttle body...
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Ignition coil and distributor side...
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Great stuff!!

And to think that putting one of those "christmas tree" air fresheners in my vehicle is a challenge for me.