3.2S Winter rebuild from Scotland

[Duffy3074]

Some bits ready to go on!

[Duffy3074]

Some before and afters!



and now



and

[Duffy3074]

Gearbox!



to




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

[Duffy3074]

Some bling and upgrades!









Going to be busy!!!

[Perfectlap]

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.

[BYprodriver]

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?

[Duffy3074]

Originally Posted by BYprodriver

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?

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.

[Duffy3074]

Originally Posted by Perfectlap

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.

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.

[golonaus]

Originally Posted by Perfectlap

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.

That's Fiat coupe. Only in Europe tho

[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!

[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?