3.2S Winter rebuild from Scotland - 986 Forum - The Community for Porsche Boxster & Cayman Owners

Duffy3074 · 01-06-2013, 09:24 AM

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://

to this

http://

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://

being replaced by copper-nickel pipes covered in heatshrink

http://

Duffy3074 · 01-10-2013, 08:34 AM

Some bits ready to go on!

Duffy3074 · 01-10-2013, 08:39 AM

Some before and afters!

and now

and

Duffy3074 · 01-10-2013, 08:42 AM

Gearbox!

to

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

Duffy3074 · 01-10-2013, 08:46 AM

Some bling and upgrades!

Going to be busy!!!

Perfectlap · 01-10-2013, 08:52 AM

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.

derfo · 01-13-2013, 05:41 AM

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 · 01-14-2013, 04:16 AM

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 · 01-14-2013, 11:48 AM

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 · 01-14-2013, 12:53 PM

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 · 01-14-2013, 02:15 PM

Quote:

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 · 01-15-2013, 06:39 AM

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.

oc-boxster · 01-10-2013, 08:52 AM

Where did you buy the short shift kit

Bruce Wayne · 01-10-2013, 11:53 AM

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 !

Porsche Chick · 01-10-2013, 02:41 PM

Love the red top! Very cool . . .

Andrew McD · 01-10-2013, 02:52 PM

Where abouts in Scotland are you Duffy?

Bfan · 01-10-2013, 03:55 PM

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.

Eric G · 01-11-2013, 03:00 AM

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

Duffy3074 · 01-11-2013, 04:59 AM

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!

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

litespeedp · 01-11-2013, 10:48 PM

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