Virginia Motor Sport Club Discussion Forums

General => Open Forum => Topic started by: rothaus on December 31, 2011, 07:39:49 AM



Title: My Garage Build - The Airboxer Garage
Post by: rothaus on December 31, 2011, 07:39:49 AM
I posted some info and picture before, and decided to move it in a new thread.

Here is it before, and unfinished:

Airboxer Garage Before (http://photosynth.net/view.aspx?cid=c8d3b64e-1039-4064-8ff7-395672018d0a&m=false&i=0:0:0&c=0:0:0&z=410.994969601037&d=-1.2427521489378:-1.17032138463811:-1.16141136510195&p=0:0&t=False)

I also used the unfinished garage to build a paint booth to paint the green 911.

(http://airboxer.com/images/part4003.jpg)

That's all gone, and the construction has started.


I was able to do the insulation of the roof last winter

R30.... the point was to do the whole roof and do not the ceiling of the garage.

Here is what the upstairs looked like

(http://airboxer.com/garage/upstairs1.jpg)

(http://airboxer.com/garage/insulation01.jpg)

Next is to install the electrical.

After the ellectrical and the insulation was done, I got some help over Labor day weekend to install the drywall.

(http://airboxer.com/garage/sheetrock.jpg)

Yes, the posting is a little behind the work.

Finished the drywall. Ceiling painted and the lights are up, trim and storage area.

(http://airboxer.com/garage/ceiling-light01.jpg)

(http://airboxer.com/garage/ceiling-light02.jpg)

(http://airboxer.com/garage/ceiling-light03.jpg)

Walls are painted

(http://airboxer.com/garage/10-15-wall.jpg)

The overhead storage is ready for paint on the trim. I installed some recessed 12V lights I still had ( brought them back from Germany when we build the house) and did not use in the house.

(http://airboxer.com/garage/10-15-storage1.jpg)

Instead of Halogen, I used LED

(http://airboxer.com/garage/10-15-led.jpg)

Installing some German 220V outlets for my left over power tools I still have from good old Germany.

(http://airboxer.com/garage/10-15-dose1.jpg)

(http://airboxer.com/garage/10-15-dose2.jpg)

(http://airboxer.com/garage/10-15-dose3.jpg)

(http://airboxer.com/garage/10-15-dose4.jpg)

Next is to finish up all the trim, the sliding doors for the over head storage, install the rest of the outlets and order the 2 post lift.




Title: Re: My Garage Build - The Airboxer Garage
Post by: whiteryder on December 31, 2011, 09:27:57 AM
That is truly awesome!!  Look forward to seeing it in person sometime.   ;D

Something wrong with your link though, I think I fixed it here:
Airboxer Garage Before (http://photosynth.net/view.aspx?cid=c8d3b64e-1039-4064-8ff7-395672018d0a&m=false&i=0:0:0&c=0:0:0&z=410.994969601037&d=-1.2427521489378:-1.17032138463811:-1.16141136510195&p=0:0&t=False%22)

BTW that's a great panorama - did you use a special camera for it, or just stitch photos together with software?

b.


Title: Re: My Garage Build - The Airboxer Garage
Post by: rothaus on December 31, 2011, 03:59:03 PM
Thanks, I fixed the original link. I used my Digital camara with Panorama support, and stitched it with photosynt.

Here more progress. I got the lift.

(http://airboxer.com/garage/lift01.jpg)

(http://airboxer.com/garage/lift02.jpg)

(http://airboxer.com/garage/lift03.jpg)

(http://airboxer.com/garage/lift04.jpg)

(http://airboxer.com/garage/lift05.jpg)

(http://airboxer.com/garage/lift06.jpg)

(http://airboxer.com/garage/lift07.jpg)

(http://airboxer.com/garage/lift08.jpg)

(http://airboxer.com/garage/lift09.jpg)

(http://airboxer.com/garage/lift10.jpg)

I have to close the door to lift the car all the way up, (http://www.garagejournal.com/forum/images/smilies/lol_hitting.gif)

but then it is high enough to stand underneed.

(http://airboxer.com/garage/lift11.jpg)

(http://airboxer.com/garage/lift12.jpg)

Cheers (http://www.garagejournal.com/forum/images/smilies/beer.gif)


Title: Re: My Garage Build - The Airboxer Garage
Post by: whiteryder on December 31, 2011, 04:19:03 PM
Oh thank you!!! 
You have now given me a great excuse for buying an engine hoist.
See?  It is useful for much more than just hoisting engines!   ;D


Title: Re: My Garage Build - The Airboxer Garage
Post by: Flynlow on January 01, 2012, 01:32:46 PM
Ausgezeichnet!

Congrats on the awesome new garage space! 


Title: Re: My Garage Build - The Airboxer Garage
Post by: rothaus on January 02, 2012, 03:33:28 PM
More to add:
Got some IKEA Wall cabinets, and found out, not everything is made in China.

Made in Slovakia !
(http://airboxer.com/garage/Dec-11_Garage01.jpg)

Made in France !
(http://airboxer.com/garage/Dec-11_Garage02.jpg)

And here it comes Made In the USA (http://www.garagejournal.com/forum/images/smilies/beer.gif)
(http://airboxer.com/garage/Dec-11_Garage03.jpg)

OK, This what it looks like now, after the last weekend, just in time. I got my very own Christmas gift, or Weihnachtsgeschenk (http://www.garagejournal.com/forum/images/smilies/bounce.gif)
(http://airboxer.com/garage/Dec-18_Garage01.jpg)

(http://airboxer.com/garage/Dec-18_Garage02.jpg)

(http://airboxer.com/garage/Dec-18_Garage03.jpg)

(http://airboxer.com/garage/Dec-18_Garage04.jpg)

I use 1x4 trim to frame it in, at the side and top. Then I chauked between the trim and the sheetrock.
(http://airboxer.com/garage/Dec-18_Garage05.jpg)



Title: Re: My Garage Build - The Airboxer Garage
Post by: rothaus on January 02, 2012, 04:04:31 PM
Installing LED's for the stairs.

Since there are a few steps, I made a jig.

(http://airboxer.com/garage/ledjig01.jpg)

Insert the pieces
(http://airboxer.com/garage/ledjig02.jpg)

Put the sheet in place
(http://airboxer.com/garage/ledjig03.jpg)

Put the guide on
(http://airboxer.com/garage/ledjig04.jpg)

(http://airboxer.com/garage/ledjig05.jpg)

Nailing
(http://airboxer.com/garage/ledjig06.jpg)

Here it is
(http://airboxer.com/garage/ledjig07.jpg)

Drill guide
(http://airboxer.com/garage/ledjig08.jpg)

Drill holes for the LED's
(http://airboxer.com/garage/ledjig09.jpg)

Installing the LED's
(http://airboxer.com/garage/dec-31-led01.jpg)

(http://airboxer.com/garage/dec-31-led02.jpg)

I added 1 3/4" to the steps, glued and screwed
(http://airboxer.com/garage/stair01.jpg)

(http://airboxer.com/garage/stair_led-01.jpg)

(http://airboxer.com/garage/stair_led-02.jpg)

(http://www.garagejournal.com/forum/images/smilies/rocker.gif)


Title: Re: My Garage Build - The Airboxer Garage
Post by: bud murray on January 02, 2012, 06:01:29 PM
YOU ARE THE MAN!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!


Title: Re: My Garage Build - The Airboxer Garage
Post by: wahoo5 on January 03, 2012, 05:56:54 PM
WOW!

David


Title: Re: My Garage Build - The Airboxer Garage
Post by: rothaus on February 20, 2012, 07:59:09 PM
I think it's time for an update.

I installed the stereo ( I still had this one sitting around, the 50 CD player died and I was not able to get rid of it)

(http://airboxer.com/garage/stereo-01.jpg)

Build a box and installed it in a place, I could not use for anything else.

I made some supports for the speakers

(http://airboxer.com/garage/stereo-02.jpg)

(http://airboxer.com/garage/stereo-03.jpg)

(http://airboxer.com/garage/stereo-04.jpg)

Sounds nice for a garage (http://www.garagejournal.com/forum/images/smilies/beer.gif)

Here is how I get the last drop out of the oil jars:

Build a little holder from scrap wood pieces.

(http://airboxer.com/garage/oil01.jpg)

Now I found a paper roll I saved from the trash and made a roll holder to scribble on or to use a piece to pack up stuff.

(http://airboxer.com/garage/paper-roll.jpg)

When the paper is gone I can use it as a dry erase bord, I glued a white left over piece of paneling on it.

Cheers


Title: Re: My Garage Build - The Airboxer Garage
Post by: whiteryder on February 20, 2012, 08:23:47 PM
I love your wooden contraptions!
Did you make the one in the VMSC trailer that holds the timing box at just the right angle?


Title: Re: My Garage Build - The Airboxer Garage
Post by: rothaus on February 21, 2012, 06:17:35 PM
If you mean the white one, Yes.

BTW: Now I have also internet in my detached garage. No Fridge yet (http://www.garagejournal.com/forum/images/smilies/beer.gif)


Title: Re: My Garage Build - The Airboxer Garage
Post by: rothaus on March 03, 2012, 06:33:47 PM
Unplanned project came up after the dyno day.

Here is what I'm doing. I still hope to have the Froggy ready for April 31.



(http://airboxer.com/garage/911-project-01.jpg)


I found that the engine had 2 broken head studs, so last year I was runing with a sick engine  ???

(http://airboxer.com/garage/911-project-02.jpg)

Here some more pictures

(http://airboxer.com/garage/911-project-03.jpg)

(http://airboxer.com/garage/911-project-04.jpg)

(http://airboxer.com/garage/911-project-05.jpg)

It never stops.

Cheers


Title: Re: My Garage Build - The Airboxer Garage
Post by: whiteryder on March 03, 2012, 06:48:13 PM
Hope you can get her ready in time!  She looks great.   :)


Title: Re: My Garage Build - The Airboxer Garage
Post by: jloehlein on March 04, 2012, 05:20:58 AM
Did you find low compression on those two cylinders?  Just wondering if you saw any signs prior to the teardown.


Title: Re: My Garage Build - The Airboxer Garage
Post by: rothaus on March 04, 2012, 06:30:20 AM
Yes, when I came home from the Dyno, I did a compression test, which didn't look that bad. However, the leakdown test showed the real picture. I found also an other issue. The resonance solenoid does not switch, must be the DME.

Back in the garage now

Cheers
 


Title: Re: My Garage Build - The Airboxer Garage
Post by: MR2_FTW on March 22, 2012, 10:05:09 AM
Are those ARP studs that were broken? I'm not sure I've ever seen someone break those.


Title: Re: My Garage Build - The Airboxer Garage
Post by: rothaus on March 23, 2012, 06:10:41 PM
The ARP are the rod bolts. My issue is the head studs. Anyway, I will fix the thing one way or another.

I picked up all the parts from LT and it looks like I'm rebuilding the engine on my own.

Cheers


Title: Re: My Garage Build - The Airboxer Garage
Post by: whiteryder on March 23, 2012, 07:04:34 PM
I picked up all the parts from LT and it looks like I'm rebuilding the engine on my own.

Will you be selling tickets?  ;D


Title: Re: My Garage Build - The Airboxer Garage
Post by: rothaus on March 24, 2012, 06:22:24 PM
As long I can finances the parts I need, with the tickets. However, you are always welcome to come and clean parts, there are a lot parts to clean.

Here is some update:

Cleaned the Crank case, the Cam tower, and polished the cams

(http://airboxer.com/garage/P1060657.jpg)

(http://airboxer.com/garage/P1060659.jpg)

(http://airboxer.com/garage/P1060664.jpg)

(http://airboxer.com/garage/P1060672.jpg)

Cheers


Title: Re: My Garage Build - The Airboxer Garage
Post by: impound on March 24, 2012, 07:42:01 PM
So Jealous of the lift!  Epic garage build.  Is the carpentry just a hobby?


Title: Re: My Garage Build - The Airboxer Garage
Post by: rothaus on March 25, 2012, 01:28:26 PM
Is the carpentry just a hobby?


It's all just a hobby, the cars, the Wood workshop, Etc.


Title: Re: My Garage Build - The Airboxer Garage
Post by: 90efcivic on April 03, 2012, 08:22:28 AM
Your block looks nice. What did you use to get everything so clean?


Title: Re: My Garage Build - The Airboxer Garage
Post by: rothaus on April 04, 2012, 09:34:09 AM
The crank case and the Cam towers are a royal pain to get clean. I used oil eater, scotch brite, scrapers, dentist tools, used up my fingers, carburater cleaner, etc. I'm getting set up with soda blasting for some other small parts, going forward.

Cheers


Title: Re: My Garage Build - The Airboxer Garage
Post by: bud murray on April 06, 2012, 09:22:55 AM
You get that soda blasta going and you will have all kinds of friends over helping so they can use it!


Title: Re: My Garage Build - The Airboxer Garage
Post by: rothaus on May 03, 2012, 05:30:31 PM
Update !

Now that I have the engine disassembled, now I'm going after the transmission, or Getriebe.

(http://airboxer.com/3600/getriebe01.jpg)

(http://airboxer.com/3600/getriebe02.jpg)

(http://airboxer.com/3600/getriebe03.jpg)

Got some part back.

(http://airboxer.com/3600/head01.jpg)

Started to put the engine back together

(http://airboxer.com/3600/3600-01.jpg)

(http://airboxer.com/3600/3600-02.jpg)

(http://airboxer.com/3600/3600-03.jpg)

More to come

However, I also had some other project in between

(http://airboxer.com/images/obelix.jpg)

As you can see by the clock I'm working at 4 AM morgens

Cheers


Title: Re: My Garage Build - The Airboxer Garage
Post by: whiteryder on May 03, 2012, 06:14:13 PM

Wow - that engine is absolutely beautiful!!
Maybe next winter I will do that with the MR2.....    ;D



Title: Re: My Garage Build - The Airboxer Garage
Post by: 90efcivic on May 05, 2012, 05:25:16 PM
did you soda blast the crankcase? it looks nice and clean


Title: Re: My Garage Build - The Airboxer Garage
Post by: rothaus on June 03, 2012, 05:49:17 PM
OK, here is an update. I made some progress.

Got the head studs installed.

(http://airboxer.com/3600/headestuds01.jpg)

Piston and cylinders are ready for installation

(http://airboxer.com/3600/cyl-pist01.jpg)

Getting there

(http://airboxer.com/3600/cyl-pist02.jpg)


One side down

(http://airboxer.com/3600/cyl-pist03.jpg)

Heads are next

(http://airboxer.com/3600/heads01.jpg)

More heads

(http://airboxer.com/3600/heads02.jpg)

Upside down

(http://airboxer.com/3600/heads03.jpg)

TimingOK

(http://airboxer.com/3600/timing-01.jpg)

I let the pictures talk

(http://airboxer.com/3600/engine-001.jpg)

(http://airboxer.com/3600/engine-002.jpg)

(http://airboxer.com/3600/engine-003.jpg)

(http://airboxer.com/3600/engine-004.jpg)

(http://airboxer.com/3600/engine-005.jpg)

Next AX I will stii run the beater

(http://farm8.staticflickr.com/7100/7055759473_f73d5842e0.jpg)

Cheers


Title: Re: My Garage Build - The Airboxer Garage
Post by: whiteryder on June 03, 2012, 07:20:22 PM
Beautiful!!  I love seeing what all the inside parts look like.

(I wish I could clean parts that well!)


Title: Re: My Garage Build - The Airboxer Garage
Post by: rothaus on July 08, 2012, 12:23:12 PM
Finaly, it's running. After a little hickup, It's back together and installed.


(http://airboxer.com/images/beer.gif)

Starting Up after install (http://airboxer.com/videos/engine/Second_time.html)

Since them I made about 80 miles, a few more and them it goes to PAS on the dyno.

Cheers


Title: Re: My Garage Build - The Airboxer Garage
Post by: whiteryder on July 08, 2012, 04:01:35 PM
That is awesome!  I wish I could have taken you up on your invitation to help.
(Next time definitely!!)


Title: Re: My Garage Build - The Airboxer Garage
Post by: rothaus on July 18, 2012, 05:59:37 PM
So the engine has now about 200 miles on it.

Took it to the dyno today:

As always

(http://airboxer.com/images/beer.gif)

http://airboxer.com/videos/dyno/dyno.html (http://airboxer.com/videos/dyno/dyno.html)

Cheers




Title: Re: My Garage Build - The Airboxer Garage
Post by: whiteryder on July 18, 2012, 07:00:23 PM
Sounds great!  How did it do compared to your last dyno?


Title: Re: My Garage Build - The Airboxer Garage
Post by: rothaus on July 20, 2012, 05:35:26 AM
Here is a run from Feb. and a run from this week.

(http://airboxer.com/images/Porsche-Dyno-2012-07-18.jpg)

Still s few things to work out, however, for the AX it should be OK.


Title: Re: My Garage Build - The Airboxer Garage
Post by: jloehlein on July 20, 2012, 05:44:58 PM
That's more like it!  220whp is around where you thought it should be, right?  Now you get to learn to drive the car for a 3rd time, I bet that extra 45hp and lots more torque throughout the whole rev range will make quite a difference.


Title: Re: My Garage Build - The Airboxer Garage
Post by: whiteryder on July 20, 2012, 08:04:36 PM
Nice improvement!
Just curious, any idea what the dip at 5200 might be coming from?


Title: Re: My Garage Build - The Airboxer Garage
Post by: ccann26 on July 23, 2012, 07:04:03 AM
Nice improvement!
Just curious, any idea what the dip at 5200 might be coming from?


Strange , its right at the magic crossing point.


Title: Re: My Garage Build - The Airboxer Garage
Post by: rothaus on July 23, 2012, 06:53:56 PM
Yes..... That's the thing I need to sort out, no more details at this time.

Most important is the difference in the torque, starting at 2500 with about 180 ft/lbs compared to 125 before.

However, the engine is mechanically OK, so it will be there on Sunday for the AX for the first shakedown after rebuild. Cross your fingers, and whatever you cann.


Title: Re: My Garage Build - The Airboxer Garage
Post by: impound on July 29, 2012, 06:53:08 PM
Here is the wallpaper I was telling you about.  It's a '76.  Awesome build.  Cheers, Mike.

http://www.speedhunters.com/2012/06/the-new-old-kid-on-the-block/

(http://cdn.speedhunters.com/wp-content/uploads/2012/06/Bisi911_02.jpg)



Title: Re: My Garage Build - The Airboxer Garage
Post by: rothaus on July 30, 2012, 06:50:48 PM
Looks like a lot of $$$$ went into that car.

I like the front end, something I like to do with the SC. Looks basically like a 964 front bumper in this case a 965 plus the added spoiler, which looks nice.

(http://cdn.speedhunters.com/wp-content/uploads/2012/06/Bisi911_05.jpg)

Maybe not Turbo wide.



Title: Re: My Garage Build - The Airboxer Garage
Post by: impound on July 30, 2012, 07:49:40 PM
I have also been following some of Japans finest.  RWB or RAUH-Welt Nakai-San has been transforming some Porsches all over the world.  They are mostly newer models but you might like: 


http://www.speedhunters.com/tag/rwb/




Title: Re: My Garage Build - The Airboxer Garage
Post by: rothaus on October 30, 2012, 05:53:19 PM
Enough playing, let's get back to the garage.

It's about time for an update.

I found a product called Deck Restore, and since it's made for the deck outside, I thought, it should work for my stairs inside that garage.

It is like a paste, and messy, but after it dried up, it's nice, and not slippery, perfect for stairs.

(http://airboxer.com/garage/stairs001.jpg)

(http://airboxer.com/garage/stairs002.jpg)

Cheers


Title: Re: My Garage Build - The Airboxer Garage
Post by: rothaus on October 30, 2012, 05:55:20 PM
OK, one more little project. Replacing the vinyl on an old bar stool for my PC in the Garage.

Here it is.

(http://airboxer.com/images/stuhl001.jpg)

Removing the legs
(http://airboxer.com/images/stuhl002.jpg)

Next, removing the bottom carpet piece
(http://airboxer.com/images/stuhl003.jpg)

(http://airboxer.com/images/stuhl004.jpg)

A piece of vinyl I still had laying around
(http://airboxer.com/images/stuhl005.jpg)

Staples 10mm
(http://airboxer.com/images/stuhl006.jpg)

Fixing on the first 2 places
(http://airboxer.com/images/stuhl007.jpg)

Then 4, pulling it nice and even
(http://airboxer.com/images/stuhl008.jpg)

Starting between the 4 sections, making sure the wrinkels are about the same
(http://airboxer.com/images/stuhl009.jpg)

All the way around
(http://airboxer.com/images/stuhl010.jpg)

Cutting of the extra material
(http://airboxer.com/images/stuhl011.jpg)

Checking and make sure it looks OK
(http://airboxer.com/images/stuhl012.jpg)

Put back on the carpet bottom and the legs
(http://airboxer.com/images/stuhl013.jpg)

There it is.
(http://airboxer.com/images/stuhl014.jpg)

Cheers


Title: Re: My Garage Build - The Airboxer Garage
Post by: ccann26 on October 30, 2012, 06:45:29 PM
 I swear Englebert has a bag of fairy dust he sprinkles on his projects. I think he spilled some in his car at the last event.


Title: Re: My Garage Build - The Airboxer Garage
Post by: whiteryder on October 30, 2012, 07:55:06 PM
I swear Englebert has a bag of fairy dust he sprinkles on his projects. I think he spilled some in his car at the last event.

No kidding!!   ;D


Hey Engelbert, how heavy is that paste you put on the steps?
Would it work well for making the un-carpeted floor of a car less slippery?



Title: Re: My Garage Build - The Airboxer Garage
Post by: rothaus on October 31, 2012, 09:28:25 AM
I swear Englebert has a bag of fairy dust he sprinkles on his projects. I think he spilled some in his car at the last event.

No kidding!!   ;D


Hey Engelbert, how heavy is that paste you put on the steps?
Would it work well for making the un-carpeted floor of a car less slippery?



I was thinking also about that, since the carpet in the green car is really thin, you can actually see the sheet metal. I was looking into the bed liner stuff. Lowes or HD has it made by Rusty O Leum.

(http://www.rustoleum.com/cbgimages/products/AU_TruckBedCoating_15oz_L.jpg)


Title: Re: My Garage Build - The Airboxer Garage
Post by: rothaus on November 05, 2012, 07:10:12 PM
Converted an old Oak desk to a work table with storage.

I had this old desk back from Germany, and since we had no use for it in the house, and it was to good to get rid of, I will use it in my garage.

Screwed the side pieces together
(http://muelhaupt.us/images/desk001.jpg)

(http://muelhaupt.us/images/desk002.jpg)

Drawers Old German style build, can't beat that.
(http://muelhaupt.us/images/desk003.jpg)

Added wheels
(http://muelhaupt.us/images/desk004.jpg)

(http://muelhaupt.us/images/desk005.jpg)

The top is actually covered with Hardwood flooring, I did way back in Germany, about 25 years ago.
Now I cut the desk top to size.
(http://muelhaupt.us/images/desk006.jpg)

Here it is installed
(http://muelhaupt.us/images/desk007.jpg)

It has also 2 pull-out shelfs
(http://muelhaupt.us/images/desk008.jpg)

Finished with a nice coat of polyurethane, so it's easy to clean.
(http://muelhaupt.us/images/desk009.jpg)

(http://muelhaupt.us/images/desk010.jpg)

Cheers


Title: Re: My Garage Build - The Airboxer Garage
Post by: whiteryder on November 05, 2012, 07:17:56 PM
Awesome!  Just the right size to put that 911 trophy on top.  ;D


Title: Re: My Garage Build - The Airboxer Garage
Post by: rothaus on November 07, 2012, 06:03:06 PM
It's getting cold outside, and I had to scrap the winshield of the 44 (my daily driver) I had this.

So I had to squeeze it in to the garage, next to the puppy and the bug.

(http://airboxer.com/images/4cars.jpg)

(http://www.garagejournal.com/forum/images/smilies/lol_hitting.gif)

Cheers


Title: Re: My Garage Build - The Airboxer Garage
Post by: gunny on November 08, 2012, 06:08:35 PM
I'm depressed, that garage is nicer than my house. I think this thread should be closed.
:)


Title: Re: My Garage Build - The Airboxer Garage
Post by: rothaus on November 12, 2012, 07:30:49 PM
Now, since I'm not travel to EU, I may continue with some more items to get completed, before I have the heat the garage.

Cheers


Title: Re: My Garage Build - The Airboxer Garage
Post by: wahoo5 on November 19, 2012, 03:47:01 PM
Englebert is getting attention on his garage projects.

http://www.garagejournal.com/2012/10/tips-tricks/ (http://www.garagejournal.com/2012/10/tips-tricks/)

David


Title: Re: My Garage Build - The Airboxer Garage
Post by: rothaus on November 19, 2012, 07:12:33 PM
Yeah, I was shocked when I saw the picture of my cheap A$$ oil container drain system on the front page.

But it works.

(http://www.garagejournal.com/forum/images/smilies/lol_hitting.gif)



Title: Re: My Garage Build - The Airboxer Garage
Post by: rothaus on November 23, 2012, 02:08:06 PM
Time for an update: A little Thanksgiving project.

Had that fan sitting around. I did not liked ir just silver. Out with the masking tape.
(http://airboxer.com/images/venti001.jpg)

(http://airboxer.com/images/venti002.jpg)

A little Red paint
(http://airboxer.com/images/venti003.jpg)

(http://airboxer.com/images/venti004.jpg)

(http://airboxer.com/images/venti005.jpg)

(http://airboxer.com/images/venti006.jpg)

(http://airboxer.com/images/venti007.jpg)

Here it is, now I'm ready for the summer.

Cheers


Title: Re: My Garage Build - The Airboxer Garage
Post by: ccann26 on November 23, 2012, 04:59:01 PM
I can see it goes much faster now !


Title: Re: My Garage Build - The Airboxer Garage
Post by: whiteryder on November 23, 2012, 05:24:46 PM
I can see it goes much faster now !

Yah, that Torch Red was a good choice!   :)


Title: Re: My Garage Build - The Airboxer Garage
Post by: rothaus on November 23, 2012, 07:03:37 PM
Just wait when you see the next addition to the garage..............


..............................................................................That's gonnnna be cooking



(http://airboxer.com/images/lol.gif)   (http://airboxer.com/images/lol.gif)   (http://airboxer.com/images/lol.gif)   (http://airboxer.com/images/lol.gif)   (http://airboxer.com/images/lol.gif)   


Title: Re: My Garage Build - The Airboxer Garage
Post by: rothaus on December 01, 2012, 04:47:58 PM
Time for an update.

Here is whats cooking:

My Pizza AKA Powder coating furnace.

I had that stove now sitting for some time. First disassembly and cleaning, prep. for Paint.

(http://airboxer.com/images/oven-001.jpg)

It's gonnna be ROT  -- Like Rothaus

(http://airboxer.com/images/oven-002.jpg)

Door will be silver, or Silber

(http://airboxer.com/images/oven-003.jpg)

Some details must be.
(http://airboxer.com/images/oven-004.jpg)

Two of the heating plates, or Kochplatten, will be deleted, too many switches and cables. Let's keep it simple.

(http://airboxer.com/images/oven-005.jpg)

Only 2 connectoer left for the plates

(http://airboxer.com/images/oven-006.jpg)

Testing all elements which are left, and they all work.

(http://airboxer.com/images/oven-007.jpg)

No worries, it's not bend. Just the picture.

(http://airboxer.com/images/oven-008.jpg)

What can I do with the holes.

(http://airboxer.com/images/oven-009.jpg)

Big holes.

(http://airboxer.com/images/oven-010.jpg)

I know, I put ein Deckel drauf, there you go. The last piece to be finished.
 
(http://airboxer.com/images/oven-011.jpg)


Cheers


Title: Re: My Garage Build - The Airboxer Garage
Post by: charlize on December 02, 2012, 03:07:33 PM
Love it, wish I had the room.


Title: Re: My Garage Build - The Airboxer Garage
Post by: rothaus on December 03, 2012, 06:34:02 PM
Here is a preview of my next restoration project.

(http://airboxer.com/images/2012_VW_001.jpg)

Cheers


Title: Re: My Garage Build - The Airboxer Garage
Post by: rothaus on December 13, 2012, 06:20:24 PM
OK, I made some progress last weekend, in between other stuff.

Here we go - no comments needed:
 
(http://airboxer.com/images/2012_VW_002.jpg)

(http://airboxer.com/images/2012_VW_003.jpg)

(http://airboxer.com/images/2012_VW_004.jpg)

(http://airboxer.com/images/2012_VW_005.jpg)

Cheers
(http://airboxer.com/images/2012_VW_006.jpg)

(http://airboxer.com/images/2012_VW_007.jpg)

(http://airboxer.com/images/2012_VW_008.jpg)

(http://airboxer.com/images/2012_VW_009.jpg)

(http://airboxer.com/images/2012_VW_010.jpg)

(http://airboxer.com/images/2012_VW_011.jpg)

(http://airboxer.com/images/2012_VW_012.jpg)


Title: Re: My Garage Build - The Airboxer Garage
Post by: jloehlein on December 15, 2012, 09:40:48 AM
Looks like it's in pretty good shape.  You gonna autocross it at least once when you're done?


Title: Re: My Garage Build - The Airboxer Garage
Post by: rothaus on December 15, 2012, 08:03:54 PM
I don't think the bug hit any cones.

An other not planned project came up. the 944 need a clutch job. Took it apart today. Ordering parts tomorrow, to be here next week. Hope it's back together next weekend before Christmess.

Cheers

 


Title: Re: My Garage Build - The Airboxer Garage
Post by: jloehlein on December 17, 2012, 05:46:07 AM
The 944 has a transaxle and torque tube, right?  Is it easier or harder to do a clutch with that setup?  I'd be interested in seeing pics if you take them...I've never really at any car with a front engine and rear transaxle in any detail.


Title: Re: My Garage Build - The Airboxer Garage
Post by: rothaus on December 17, 2012, 04:35:01 PM
Here is what it looks like.

Car on the lift

(http://airboxer.com/images/944_clutch001.jpg)

Exhaust has to come off.

(http://airboxer.com/images/944_clutch002.jpg)

I lowered the transmission on the bridge jack.

(http://airboxer.com/images/944_clutch003.jpg)

(http://airboxer.com/images/944_clutch004.jpg)

Disconnect the torq tube and moved it back, as far as possible

(http://airboxer.com/images/944_clutch005.jpg)

(http://airboxer.com/images/944_clutch006.jpg)

Removed the clutch casing and here it is.

(http://airboxer.com/images/944_clutch007.jpg)

Looks like the car still had the original clutch with the rubber center.

(http://airboxer.com/images/944_clutch008.jpg)

The good thing is that I just last month found that somebody on the Porsche forum had a good clutch for sale, and I got it for 70 bucks instean 700 new.

(http://airboxer.com/images/944_clutch009.jpg)

The flywheel looks good also.

(http://airboxer.com/images/944_clutch010.jpg)

Got new T/O bearing, the Pilot, and 2 small bearing for the fork on Order. Should have it by end of this week, and that puppy goes back together. The reason I took it apart I some noise comming from the clutch area when the clutch was in. As soon I pushed it just a little the noise was gone. The old clutch plate was about ready for replacement. It's crazy but a job like this can go quickly up to 2k.

Cheers
 


Title: Re: My Garage Build - The Airboxer Garage
Post by: rothaus on December 24, 2012, 06:51:54 AM
It's all back together, no more noisy T/O bearing.

On the 911 I would have done this a lot quicker

 (http://airboxer.com/images/lol.gif)

Cheers


Title: Re: My Garage Build - The Airboxer Garage
Post by: rothaus on January 01, 2013, 02:41:58 PM
I had this trunk lid from a '68 912 sitting around. It has some pitting on the inside frame, and is not good to use for restoration anymore, so I made some Garage art out of it. Got it mounted today.

(http://airboxer.com/images/beer.gif)

(http://airboxer.com/images/Hood_59.jpg)

Happy New Year


Title: Re: My Garage Build - The Airboxer Garage
Post by: wahoo5 on January 02, 2013, 02:44:14 PM
Brumos. Very nice.


Title: Re: My Garage Build - The Airboxer Garage
Post by: rothaus on January 22, 2013, 06:15:19 PM
Here is an update. Had to many other things going, however, last weekend I made a little progress.

Disassembly of the top.

(http://airboxer.com/images/2013-01-19_VW_01-.jpg)


(http://airboxer.com/images/2013-01-19_VW_02-.jpg)


(http://airboxer.com/images/2013-01-19_VW_03-.jpg)

Outer skin is off
(http://airboxer.com/images/2013-01-19_VW_04-.jpg)

Got some rotten wood
(http://airboxer.com/images/2013-01-19_VW_05-.jpg)

All is gone
(http://airboxer.com/images/2013-01-19_VW_06-.jpg)

Next, the sound mats, with heater gun and scraper
(http://airboxer.com/images/2013-01-19_VW_07-.jpg)


(http://airboxer.com/images/2013-01-19_VW_08-.jpg)

Doors off, they have some rust at the bottom, details later.
(http://airboxer.com/images/2013-01-19_VW_09-.jpg)

Engine is also out, a little easier as the 911.
(http://airboxer.com/images/2013-01-19_VW_10-.jpg)


(http://airboxer.com/images/2013-01-20_VW_01.jpg)

The dash is gone, the wire harnes from the fuse box to the rear end as well, and the windshield.

Clean-up time and beer time.
(http://airboxer.com/images/2013-01-20_VW_02.jpg)

Next weekend front wire harness and whatever is left.

Cheers
Engelbert


Title: Re: My Garage Build - The Airboxer Garage
Post by: rothaus on February 01, 2013, 06:42:34 PM
Time for an update:

Last Weekened I got back on it. Removed the rest of the wire harness.

Disassembled the doors etc.

Here some pictures

What happen to this car ????

(http://airboxer.com/images/2013-01-26-01.jpg)

Why does it have a hole, and it looks like somebody cut it out with a chainsaw.

(http://airboxer.com/images/2013-01-26-02.jpg)

Anyway, I think I need to fix this, besides other holes.

Here is one door. It has some rust at the bottom.

(http://airboxer.com/images/2013-01-26-03.jpg)

Door hardware Art picture

(http://airboxer.com/images/2013-01-27-01.jpg)

Happy Weekend


Title: Re: My Garage Build - The Airboxer Garage
Post by: jloehlein on February 02, 2013, 04:58:50 AM
Maybe the hole is to fit some skis?  I love how simple the car is, overall.


Title: Re: My Garage Build - The Airboxer Garage
Post by: whiteryder on February 05, 2013, 04:00:20 PM
When you're done with all that, here's a smaller project you might want to try.  ;D

http://www.youtube.com/watch?v=m3KdpzL3Hkk



Title: Re: My Garage Build - The Airboxer Garage
Post by: rothaus on February 05, 2013, 08:10:40 PM
When you're done with all that, here's a smaller project you might want to try.  ;D

http://www.youtube.com/watch?v=m3KdpzL3Hkk



To small for me. I like 1 : 1 Scale, and six cylinders

(http://airboxer.com/3600/cyl-pist01.jpg)

and 12 spark plugs is enough.

(http://airboxer.com/3600/head01.jpg)

Did some work on the 911 last weekend.

Beefed up the torsion bars a few notches, alignment, etc. Need to fine tune the corner balance, etc.

Cheers


Title: Re: My Garage Build - The Airboxer Garage
Post by: whiteryder on February 05, 2013, 08:11:52 PM

Beautiful!!   ...and I don't need my glasses to see it, either.   :)



Title: Re: My Garage Build - The Airboxer Garage
Post by: ccann26 on February 15, 2013, 05:41:29 PM


  A can of Window weld and a caulk gun should do it........


Title: Re: My Garage Build - The Airboxer Garage
Post by: jloehlein on February 15, 2013, 05:55:10 PM
Good to hear!  Suspension is overrated.


Title: Re: My Garage Build - The Airboxer Garage
Post by: rothaus on February 15, 2013, 08:20:56 PM
I think you guys in the wrong thread...... This is the Airboxer Garage Thread.

Which is

(http://airboxer.com/images/beer.gif)









Cheers


Title: Re: My Garage Build - The Airboxer Garage
Post by: whiteryder on February 15, 2013, 08:47:35 PM

I think this is the forum you were looking for....
http://www.vmsc.org/index.php?option=com_smf&Itemid=26&topic=1947.msg10169

...although that also appears to have gotten a bit off topic.   ;)


Title: Re: My Garage Build - The Airboxer Garage
Post by: whiteryder on June 01, 2013, 07:43:58 PM
How's the Beetle coming along?

I hate to think of you without a project... if you ever run dry here's a bit of inspiration:
http://www.speedhunters.com/2013/05/race-taxi-the-porsche-bi-turbo-bus/


Title: Re: My Garage Build - The Airboxer Garage
Post by: rothaus on June 03, 2013, 05:47:31 PM
I like the bus.

Enough projects going on, don't think I'm bored.

I picked up a set of 16 inchers 7 and 8 for the white SC, the car you saw on Saturday.

Here I have them already stripped. Paint and anodizing removed.

(http://airboxer.com/images/Fuchs_16-01.jpg)

Lips are polished and taped for painting

(http://airboxer.com/images/Fuchs_16-02.jpg)

Painted

(http://airboxer.com/images/Fuchs_16-03.jpg)

Center caps restored

(http://airboxer.com/images/Fuchs_16-04.jpg)

Ready for some new rubber

(http://airboxer.com/images/Fuchs_16-05.jpg)



Title: Re: My Garage Build - The Airboxer Garage
Post by: rothaus on June 27, 2013, 05:53:34 PM
An other little project. Drilled door handles for Froggy

A while ago I got these door handles and finally I got around to do it to them.

I used some masking tape and marked where I want to have the holes. I decided on 4 holes.

(http://airboxer.com/images/holi-handle01.jpg)

I started with a 3.5mm drill bit.

(http://airboxer.com/images/holi-handle02.jpg)

(http://airboxer.com/images/holi-handle03.jpg)

(http://airboxer.com/images/holi-handle04.jpg)

Moving to a larger drill bit. In this case I made the final hole 7mm

(http://airboxer.com/images/holi-handle05.jpg)

(http://airboxer.com/images/holi-handle06.jpg)

(http://airboxer.com/images/holi-handle07.jpg)

I used a larger drill bit to make chamfer

(http://airboxer.com/images/holi-handle08.jpg)

Now rounding up the sharp edges with this little tool.

(http://airboxer.com/images/holi-handle09.jpg)

After that I used a little polishing tip and my Dremel to finsh it up.

(http://airboxer.com/images/holi-handle10.jpg)

(http://airboxer.com/images/holi-handle11.jpg)

Here is a picture of the chromed door handles. To be installed this weekend

(http://airboxer.com/images/holi-handle12.jpg)


Next will be the update of the extension of the Airboxer Garage

Cheers
Engelbert


Title: Re: My Garage Build - The Airboxer Garage
Post by: rothaus on July 05, 2013, 03:28:19 PM
The handles are installed.

Before

(http://airboxer.com/images/holi-handle13.jpg)

After

(http://airboxer.com/images/holi-handle14.jpg)

(http://airboxer.com/images/holi-handle15.jpg)

Will test it this Sunday at the AX

Cheers
Engelbert


Title: Re: My Garage Build - The Airboxer Garage
Post by: catapultkid on July 08, 2013, 08:23:12 AM
Nice touch. Its always the little things that really make the project come to life.


Title: Re: My Garage Build - The Airboxer Garage
Post by: rothaus on July 16, 2013, 05:21:53 PM
It's a German thing ????

(http://airboxer.com/images/beer.gif)

http://www.petrolicious.com/the-911-s-allure-is-a-german-thing (http://www.petrolicious.com/the-911-s-allure-is-a-german-thing)

Cheers
Engelbert


Title: Re: My Garage Build - The Airboxer Garage
Post by: rothaus on July 21, 2013, 05:59:26 PM
Fixing the 944

Had some issues. Found Oil in the cooling system, and some cooling fluid in the Oil system. This can never happen to my 911.

Here is what I did.

Disassembled the Oil cooler. cleaned it and replaced the O-rings and put it back together. Then I learned that Porsche recommends to replace the Rod bearings. Oh $hit.

Here we go:

Here is what I got my self into with this Water cooled car.

This is what the oil looked like.

(http://muelhaupt.us/images/Oel001.jpg)

(http://muelhaupt.us/images/Oel002.jpg)

I was digging in and now the oil pan is out, using this handy jack from the trunk of the 944

(http://muelhaupt.us/images/Oel003.jpg)

(http://muelhaupt.us/images/Oel004.jpg)

The rod bearings are out, and they don't look that bad, however, new once are ordered, plus the gasket, new rod nuts, new engine mounts, tie-rod ends, and bellows, extra oil filters, etc.

(http://muelhaupt.us/images/Oel005.jpg)

The journals look like new, So I hope I get my beater back together next weekend.

(http://muelhaupt.us/images/Oel006.jpg)

Still need to flush the cooling system and the oil system.

Cheers
Engelbert


Title: Re: My Garage Build - The Airboxer Garage
Post by: rothaus on July 29, 2013, 05:23:56 PM
Got it all back together, all looks OK. Flushed the oil and water system once. New Oil and filter in today. One more flush, and hope all it good.

More to come

Cheers
Engelbert


Title: Re: My Garage Build - The Airboxer Garage
Post by: catapultkid on July 30, 2013, 02:19:14 PM
What a pain. I've never seen an oil cooler fail like that but I have heard of it. At least it wasn't the head gasket which would have been my first guess.


Title: Re: My Garage Build - The Airboxer Garage
Post by: jloehlein on July 30, 2013, 04:39:54 PM
I had an oil cooler fail like that in the Caprice.  Of course, my approach to fixing it was to buy a parts car.


Title: Re: My Garage Build - The Airboxer Garage
Post by: rothaus on July 30, 2013, 05:30:21 PM
The head gasket is what I was thinking also. After some research, a compression test, leak-down test, it was clear the damn oil cooler is the issue. BTW it was about $20 to fix the oil cooler leak, but about 10 hours of work.

I love my air-cooled cars.

Still, the 944 is a really fun car and I'm not giving it up. I'm just realized that I have more Water-cooled Porsches than Air-cooled once. I need to find a 930 to make it even.

Cheers
Engelbert


Title: Re: My Garage Build - The Airboxer Garage
Post by: rothaus on August 09, 2013, 03:08:44 PM
The 944 is back together and I have my DD back. A few other items were also fixed, since I had to remove the cross member to get to the oil pan.

It's maybe a little hot right now without AC. Need to see how I can fix that.

However, back to the garage.

Here is what it was before

(http://airboxer.com/garage/garage_ex01.jpg)

This was the idea

(http://airboxer.com/garage/garage_ex02.jpg)

This is what it looks like today

(http://airboxer.com/images/garage-july-13.jpg)


Cheers
Engelbert


Title: Re: My Garage Build - The Airboxer Garage
Post by: gunny on August 09, 2013, 05:05:29 PM
Nice, All You Need Now Is A Tire Machine


Title: Re: My Garage Build - The Airboxer Garage
Post by: ricardodemoraes on August 09, 2013, 05:27:19 PM
Now, that's a garage!


Title: Re: My Garage Build - The Airboxer Garage
Post by: rothaus on August 10, 2013, 04:40:26 AM
Nice, All You Need Now Is A Tire Machine

I agree, but I have no space for it.


Title: Re: My Garage Build - The Airboxer Garage
Post by: rothaus on August 18, 2013, 01:17:42 PM
Another little mini project.

I had this Corona clock floating around for a while now, and instead to just junk it, I want to make something for the Airboxer garage.

Before

(http://airboxer.com/images/clock001.jpg)

After

(http://airboxer.com/images/clock002.jpg)

Cheers
Engelbert


Title: Re: My Garage Build - The Airboxer Garage
Post by: gunny on August 18, 2013, 07:37:12 PM
Weird clock!
Never seen a 20 hour clock before! I think it needs to be redone with Corvettes

Gunny


Title: Re: My Garage Build - The Airboxer Garage
Post by: jloehlein on August 19, 2013, 06:29:48 AM
It's metric, 10 hours...with half hours as well.


Title: Re: My Garage Build - The Airboxer Garage
Post by: rothaus on August 19, 2013, 04:52:19 PM
Weird clock!
Never seen a 20 hour clock before! I think it needs to be redone with Corvettes

Gunny

You mean Crevettes

(http://t3.gstatic.com/images?q=tbn:ANd9GcRwkxl8ZN2NccmVax6LvpEJhQvkMc0PUGLflz7P0bjGFXUopfuwWw)


Title: Re: My Garage Build - The Airboxer Garage
Post by: rothaus on October 05, 2013, 05:48:55 AM
Picked up a new project.

This will have to wait until the Beetle is done.

(http://airboxer.com/images/on-the-way-homeS.jpg)

Cheers
Engelbert


Title: Re: My Garage Build - The Airboxer Garage
Post by: catapultkid on October 08, 2013, 01:38:19 PM
Love to see this new project you speak of. I'll wait patiently.

Is it Autox or street car based?


Title: Re: My Garage Build - The Airboxer Garage
Post by: wahoo5 on October 08, 2013, 05:06:59 PM
Can't wait to see you take the wraps off this one. I am guessing '70s 911. Have you ever seen what Singer does to old 911s?


Title: Re: My Garage Build - The Airboxer Garage
Post by: rothaus on October 08, 2013, 07:30:21 PM
Can't wait to see you take the wraps off this one. I am guessing '70s 911. Have you ever seen what Singer does to old 911s?

You are close 1970 911T

Actually Singer take cars like a 964 and backdates them, so they look like a long hood, pre 74. and makes them ridicules expensive.

Here a little preview from the inside. Miles are original.

(http://airboxer.com/images/innen-70-001.jpg)

More to come.

Cheers
Engelbert


Title: Re: My Garage Build - The Airboxer Garage
Post by: wahoo5 on October 08, 2013, 09:28:08 PM
Sweet. It should keep you busy over the winter.


Title: Re: My Garage Build - The Airboxer Garage
Post by: rothaus on November 02, 2013, 03:32:48 PM
Actually this will keep me busy over the winter.

Made some progress on the beetle, besides other stuff.

Drained and removed the gas tank.

(http://airboxer.com/images/beettle_Oct-13-01.jpg)

(http://airboxer.com/images/beettle_Oct-13-02.jpg)

Next, the front suspension

(http://airboxer.com/images/beettle_Oct-13-03.jpg)


Is now also gone.

(http://airboxer.com/images/beettle_Oct-13-04.jpg)

(http://airboxer.com/images/beettle_Oct-13-05.jpg)

Now I need to make some braces for the upper part of the body, where the doors were. And then split to body from the chassis.

Cheers
Engelbert


Title: Re: My Garage Build - The Airboxer Garage
Post by: rothaus on November 10, 2013, 06:46:31 PM
Made some progress this weekend.

Installed braces

(http://airboxer.com/images/beetle-2013-11-00101.jpg)

(http://airboxer.com/images/beetle-2013-11-001.jpg)

Separating the chassis and the upper part

(http://airboxer.com/images/beetle-2013-11-002.jpg)

(http://airboxer.com/images/beetle-2013-11-003.jpg)

(http://airboxer.com/images/beetle-2013-11-004.jpg)

Transmission removed

(http://airboxer.com/images/beetle-2013-11-005.jpg)

Rear suspension removed

(http://airboxer.com/images/beetle-2013-11-006.jpg)

It's almost like Overhaul'n

But this is just a one-man show

Cheers
Engelbert


Title: Re: My Garage Build - The Airboxer Garage
Post by: 500KEG8 on November 12, 2013, 06:01:14 AM
I'm impressed by this build, I love all the detail involved! Thank you for posting you pictures, and I look forward to seeing more your progress!


Title: Re: My Garage Build - The Airboxer Garage
Post by: rothaus on November 18, 2013, 05:44:42 PM
Some Blech arrived this week for the Käfer.

(http://airboxer.com/images/blech-01.jpg)



Title: Re: My Garage Build - The Airboxer Garage
Post by: rothaus on November 26, 2013, 05:27:00 PM
Made some progress last weekend.

Old Floor pans removed

(http://airboxer.com/images/beetle-2013-11-23_1.jpg)

Cleaning up the old welds

(http://airboxer.com/images/beetle-2013-11-23_2.jpg)

(http://airboxer.com/images/beetle-2013-11-23_3.jpg)

Test fitting the new boards, just fitted with sheet metal screws

(http://airboxer.com/images/beetle-2013-11-23_4.jpg)

They actually did fit really good, even they are made in Brazil... LOL

(http://airboxer.com/images/beetle-2013-11-23_5.jpg)

Fitting the schuh

(http://airboxer.com/images/beetle-2013-11-23_6.jpg)

Getting closer

(http://airboxer.com/images/beetle-2013-11-23_7.jpg)

Looks like the schuh fits

(http://airboxer.com/images/beetle-2013-11-23_8.jpg)

(http://airboxer.com/images/beetle-2013-11-23_9.jpg)

Even the holes line up

(http://airboxer.com/images/beetle-2013-11-23_10.jpg)

Back apart and finish welded

(http://airboxer.com/images/beetle-2013-11-23_11.jpg)

Sunday night, all cleaned up and back in the garage. Now we are ready for a nice bier.

(http://airboxer.com/images/beetle-2013-11-23_12.jpg)

Cheers
Engelbert


Title: Re: My Garage Build - The Airboxer Garage
Post by: whiteryder on November 26, 2013, 08:18:53 PM

Engelbert, you are amazing.
Very talented, and maybe a little bit lucky too.   ;D

I enjoy seeing the saga unfold.


Title: Re: My Garage Build - The Airboxer Garage
Post by: rothaus on November 28, 2013, 08:23:34 AM
Yes, sometimes I'm lucky. Today, the 24lb turkey is stuffed with home made bratwurst meat, got a nice sweatshirt with bacon, and is ready for the heat treatment.

(http://community.swr3.de/img/bild/n/ka47AZ.jpg)

Happy Thanksgiving !

Engelbert


Title: Re: My Garage Build - The Airboxer Garage
Post by: ccann26 on November 28, 2013, 10:04:24 AM

 Oh my ! Englebert you really are a genius.


Title: Re: My Garage Build - The Airboxer Garage
Post by: whiteryder on November 29, 2013, 08:17:46 AM

Do you have an "after" picture to share?   ;D


Title: Re: My Garage Build - The Airboxer Garage
Post by: rothaus on November 29, 2013, 08:38:36 AM
Here it is

(http://airboxer.com/images/Turkey_2013-01.jpg)

(http://airboxer.com/images/Turkey_2013-02.jpg)

Want some ?


Title: Re: My Garage Build - The Airboxer Garage
Post by: rothaus on December 06, 2013, 06:01:32 PM
Finish eating, back to the car. Not many pictures, however, I made some progress last weekend.

Applying seam sealer and primer

(http://airboxer.com/images/P1110347s.jpg)

And the final coat at the bottom.

(http://airboxer.com/images/P1110370s.jpg)

Did some cleaning/blasting of small part for the rear suspension, etc. prepping for powder coat.

(http://airboxer.com/images/P1110372s.jpg)

More this weekend.


Title: Re: My Garage Build - The Airboxer Garage
Post by: rothaus on December 25, 2013, 08:27:17 AM
Time for an update.

Got a few things done during the last couple weekends.

The chassis is done, also at the top, and ready for assembly.

(http://airboxer.com/images/P1110393s.jpg)

Did some power coating. The stove works OK, however, I need to watch the temperature. Some improvement is needed for the temperature control.

(http://airboxer.com/images/131222-02.jpg)

Finally I had it with the small blasting cabinet.

Ordered some bits and pieces and got 2 sheets of plywood.

BUILDING A GOOD SIZE BLASTING CABINET 48 X 24 X 32

(http://airboxer.com/images/blast001.jpg)

Cutting out for the window

(http://airboxer.com/images/blast002.jpg)

And the holes for the gloves

(http://airboxer.com/images/blast003.jpg)

Caulking all the cracks

(http://airboxer.com/images/blast004.jpg)

Building the bottom part

(http://airboxer.com/images/blast005.jpg)

(http://airboxer.com/images/blast006.jpg)

Cutting a hole for the light

(http://airboxer.com/images/blast007.jpg)

(http://airboxer.com/images/blast008.jpg)

Ready for primer and paint

(http://airboxer.com/images/blast009.jpg)

Still had that blue paint, and it goes nice with the lift

(http://airboxer.com/images/blast010.jpg)

Assembly of top and bottom part

(http://airboxer.com/images/blast011.jpg)

Now get some legs

(http://airboxer.com/images/blast012.jpg)

Here we go, it's standing up.

(http://airboxer.com/images/blast013.jpg)

I just used some wire shelf pieces inside.

(http://airboxer.com/images/blast014.jpg)

Building the top light

(http://airboxer.com/images/blast015.jpg)

I had the 100W 12 DC driver sitting a round, and also 2 HID ballasts and bulbs

(http://airboxer.com/images/blast016.jpg)

Some flashing left over makes a nice reflector

(http://airboxer.com/images/blast017.jpg)

The 2 HID bulbs use only 70W

(http://airboxer.com/images/blast018.jpg)

Here a quick test of the light

(http://airboxer.com/images/blast019.jpg)

Looks like I have enough light in there

(http://airboxer.com/images/blast020.jpg)

Here it is ready for a blast

(http://airboxer.com/images/blast021.jpg)

Here it is the top one to be done, bottom one is clean and ready for powder coating. Hope I can fit it in the stove.

(http://airboxer.com/images/131222-01.jpg)


Cheers
Engelbert


Title: Re: My Garage Build - The Airboxer Garage
Post by: jloehlein on December 25, 2013, 09:46:13 AM
That's pretty awesome.


Title: Re: My Garage Build - The Airboxer Garage
Post by: wahoo5 on December 27, 2013, 09:43:15 AM
Very impressive, Englebert.


Title: Re: My Garage Build - The Airboxer Garage
Post by: Curmudgeon on December 28, 2013, 10:13:36 AM
Silly me ... I thought you were talking about the building a car, not building the garage !!  ;)


Title: Re: My Garage Build - The Airboxer Garage
Post by: rothaus on January 03, 2014, 06:59:49 PM
OK, it's time for an update....

Bending and installing some brake lines

(http://airboxer.com/images/P1110492s.jpg)

Put the rear suspension back together

(http://airboxer.com/images/P1110493s.jpg)

New bushings

(http://airboxer.com/images/P1110494s.jpg)

Powder coated spring plates and covers

(http://airboxer.com/images/P1110495s.jpg)

(http://airboxer.com/images/P1110496s.jpg)

Now with the control arms

(http://airboxer.com/images/P1110507s.jpg)

Moving back the to body, since I waiting for some suspension parts.

(http://airboxer.com/images/P1110510s.jpg)

New front piece installed with the left and right bumper support section

(http://airboxer.com/images/P1110542s.jpg)

Attacking the rear part of the wheel well, which looked like an easy task.

(http://airboxer.com/images/P1110543s.jpg)

Not so... more under the skin

(http://airboxer.com/images/P1110549s.jpg)

(http://airboxer.com/images/P1110558s.jpg)

(http://airboxer.com/images/P1110562s.jpg)

Reconstructing all the pieces

(http://airboxer.com/images/P1110566s.jpg)

(http://airboxer.com/images/P1110571s.jpg)

(http://airboxer.com/images/P1110574s.jpg)

(http://airboxer.com/images/P1110576s.jpg)

Welding it back in

(http://airboxer.com/images/P1110585s.jpg)

(http://airboxer.com/images/P1110591s.jpg)

More stuff to fabricate

(http://airboxer.com/images/P1110593s.jpg)

(http://airboxer.com/images/P1110595s.jpg)

(http://airboxer.com/images/P1110600s.jpg)

(http://airboxer.com/images/P1110603s.jpg)

The skin, finally

(http://airboxer.com/images/P1110606s.jpg)

(http://airboxer.com/images/P1110607s.jpg)

All welded in and cleaned up. The next piece is the brace of the strut tower.

(http://airboxer.com/images/P1110610s.jpg)

More coming soon.

Cheers
Engelbert










Title: Re: My Garage Build - The Airboxer Garage
Post by: rothaus on January 05, 2014, 06:29:37 PM
Little update. Completed the right side around the front wheel well, and now move on to the left one.

Strut tower brace is back on, and one more small section to cut out and weld a new piece in.

(http://airboxer.com/images/P1110615s.jpg)

(http://airboxer.com/images/P1110617s.jpg)

Now we are moving to the left side

Doesn't look that bad at first

(http://airboxer.com/images/P1110618s.jpg)

A bit crunchy here

(http://airboxer.com/images/P1110619s.jpg)

Once the outside skin is gone, it looks not that good any more

(http://airboxer.com/images/P1110625s.jpg)

More crunchy stuff.. outch

(http://airboxer.com/images/P1110626s.jpg)

Need to make some cuts

(http://airboxer.com/images/P1110628s.jpg)

One piece is gone.

(http://airboxer.com/images/P1110629s.jpg)

It is getting thin.

(http://airboxer.com/images/P1110634s.jpg)

Looks like a few pieces to fabricate... next weekend.

Cheers
Engelbert


Title: Re: My Garage Build - The Airboxer Garage
Post by: rothaus on January 15, 2014, 06:41:37 PM
Can't wait to see you take the wraps off this one. I am guessing '70s 911. Have you ever seen what Singer does to old 911s?

OK, here some pictures:

(http://airboxer.com/images/70-P1110637s.jpg)

Here he sits next to his younger brother, my '71 911T

(http://airboxer.com/images/70-P1110636s.jpg)

The engine need to be rebuild, since the car was sitting over 10 years. The engine still turns over by hand.

(http://airboxer.com/images/70-P1110638s.jpg)

Most of the interior parts are in good condition

(http://airboxer.com/images/70-P1110639s.jpg)

(http://airboxer.com/images/70-P1110652s.jpg)

(http://airboxer.com/images/70-P1110654s.jpg)

Still got the Blaupunkt Radio, which I believe could be the original

(http://airboxer.com/images/70-P1110656s.jpg)

There are a few spots that need attention, and a little welding. Will see once I got all the interior removed, as well the engine and suspension

(http://airboxer.com/images/70-P1110640s.jpg)

The front suspension pan was replaced at one point and all looks clean and no rust.

(http://airboxer.com/images/70-P1110641s.jpg)

(http://airboxer.com/images/70-P1110646s.jpg)

Cheers
Engelbert



Title: Re: My Garage Build - The Airboxer Garage
Post by: catapultkid on January 16, 2014, 06:39:50 AM
Rust repair... so much fun. Looks good man!


Title: Re: My Garage Build - The Airboxer Garage
Post by: rothaus on January 21, 2014, 07:25:25 PM
OK.... Let's get back on the VW

I decided to replace the complete reinforcement rail on the left side, since I repaired that piece (I'm shocked) 15 years ago. This way I will have a nice strong base.

OK, enough of this, I will move to something more fun. Re-assembly of the chassis:

Preparing some brake lines

(http://airboxer.com/images/P1110676s.jpg)

(http://airboxer.com/images/P1110678s.jpg)

And installing them, as well the master and rear cylinders

(http://airboxer.com/images/P1110680s.jpg)

(http://airboxer.com/images/P1110685s.jpg)

(http://airboxer.com/images/P1110690s.jpg)

(http://airboxer.com/images/P1110694s.jpg)

And the brake shoes

(http://airboxer.com/images/P1110726s.jpg)

and drums

(http://airboxer.com/images/P1110754s.jpg)

Ok... now we are moving to the right rear corner

(http://airboxer.com/images/P1110732s.jpg)

(http://airboxer.com/images/P1110733s.jpg)

(http://airboxer.com/images/P1110734s.jpg)

It didn't look that bad, however, as more you dig in....

(http://airboxer.com/images/P1110735s.jpg)

And before you know it the hole get's bigger

(http://airboxer.com/images/P1110736s.jpg)

(http://airboxer.com/images/P1110742s.jpg)

(http://airboxer.com/images/P1110750s.jpg)

Trying to find the good material to weld on to.

(http://airboxer.com/images/P1110756s.jpg)

Fabricating some new pieces

(http://airboxer.com/images/P1110758s.jpg)

And weld them in. No comments needed

(http://airboxer.com/images/P1110760s.jpg)

(http://airboxer.com/images/P1110761s.jpg)

(http://airboxer.com/images/P1110762s.jpg)

(http://airboxer.com/images/P1110770s.jpg)

(http://airboxer.com/images/P1110772s.jpg)

(http://airboxer.com/images/P1110773s.jpg)

Finishing up the outside

(http://airboxer.com/images/P1110774s.jpg)

(http://airboxer.com/images/P1110776s.jpg)

To be continued

Cheers
Engelbert



Title: Re: My Garage Build - The Airboxer Garage
Post by: catapultkid on January 22, 2014, 02:33:30 PM
Looking good. I hope you at least bring it out once for show and tell.


Title: Re: My Garage Build - The Airboxer Garage
Post by: gunny on January 22, 2014, 04:56:00 PM
Hey just a FYI.
Maybe start a part II thread. This one takes a while to load (all the pictures)

Gunny


Title: Re: My Garage Build - The Airboxer Garage
Post by: rothaus on January 22, 2014, 05:30:23 PM
I like your Avatar. A friend of mine has a large version of it hanging in his house. LOL.

regarding the pictures. It's up to the settings in the forum to limit the number of pictures per post or posts per page.

Just noticed that this thread has 17760 views

Cheers
Engelbert



Title: Re: My Garage Build - The Airboxer Garage
Post by: rothaus on January 22, 2014, 05:33:20 PM
Ha, just started a new page

(http://airboxer.com/images/lol.gif) (http://airboxer.com/images/lol.gif) (http://airboxer.com/images/lol.gif) (http://airboxer.com/images/lol.gif) (http://airboxer.com/images/lol.gif) (http://airboxer.com/images/lol.gif) (http://airboxer.com/images/lol.gif) (http://airboxer.com/images/lol.gif) (http://airboxer.com/images/lol.gif) (http://airboxer.com/images/lol.gif) (http://airboxer.com/images/lol.gif) (http://airboxer.com/images/lol.gif) (http://airboxer.com/images/lol.gif) (http://airboxer.com/images/lol.gif) (http://airboxer.com/images/lol.gif) (http://airboxer.com/images/lol.gif)


Title: Re: My Garage Build - The Airboxer Garage
Post by: rothaus on January 22, 2014, 05:35:26 PM
Looking good. I hope you at least bring it out once for show and tell.


Yes, I know when it ready, Claudia will bring it out to an AX instead the Puppy.

Cheers
Engelbert


Title: Re: My Garage Build - The Airboxer Garage
Post by: rothaus on January 30, 2014, 05:57:53 PM
Little update:

Finishing up that bottom corner

(http://airboxer.com/images/P1110779s.jpg)

One more hole to fix from the outside. The bottom piece is welded in.

(http://airboxer.com/images/P1110784s.jpg)

(http://airboxer.com/images/P1110792s.jpg)

The last outside piece welded and cleaned up.

(http://airboxer.com/images/P1110793s.jpg)

(http://airboxer.com/images/P1110795s.jpg)

What looked as surface rust, turned out to be also bad. Another piece to make.

(http://airboxer.com/images/P1110798s.jpg)

(http://airboxer.com/images/P1110799s.jpg)

Making a template from brown paper bags. Fitting the piece.

(http://airboxer.com/images/P1110802s.jpg)

(http://airboxer.com/images/P1110804s.jpg)

 This was the last piece of the rear right section. 

(http://airboxer.com/images/P1110810s.jpg)

More next weekend

Cheers
Engelbert



Title: Re: My Garage Build - The Airboxer Garage
Post by: rothaus on February 02, 2014, 06:54:19 PM
Looks like I got the easy parts done.

Now moving to the left side.

(http://airboxer.com/images/P1110825s.jpg)

The support rail need to go, I patched it up 15 years ago.

(http://airboxer.com/images/P1110827s.jpg)

Removed the rail, but WTF ??

(http://airboxer.com/images/P1110828s.jpg)

More rust

(http://airboxer.com/images/P1110830s.jpg)

(http://airboxer.com/images/P1110832s.jpg)

Heating channel is also bad, as well the plate between the rail and the channel.

(http://airboxer.com/images/P1110834s.jpg)

Not much left

(http://airboxer.com/images/P1110844s.jpg)

Now I need a new heater channel, and the plate that goes between. Also some more pieces to fabricate.

(http://airboxer.com/images/P1110846s.jpg)

More next weekend.

Cheers
Engelbert



Title: Re: My Garage Build - The Airboxer Garage
Post by: rothaus on February 16, 2014, 04:37:01 PM
Still waiting for the heater channel. No, what can I do to use the time.

Axle shafts need new CV joints.

Here is the old stuff. I cleaned one to see what the look like.

(http://airboxer.com/images/P1110858s.jpg)

New parts I had already ordered.

(http://airboxer.com/images/P1110859s.jpg)

(http://airboxer.com/images/P1110860s.jpg)

I go put the grease is when I install them. Now they are ready and I just put them away.

(http://airboxer.com/images/P1110863s.jpg)

So now, what's next ? I thought, lets crack open the transmission, and put all new seals in. There was no problem, but it was leaking. Draining the oil.

(http://airboxer.com/images/P1110867s.jpg)

Disassembly has started.

(http://airboxer.com/images/P1110871s.jpg)

(http://airboxer.com/images/P1110872s.jpg)

I had to build a little jack to press out the shaft.

(http://airboxer.com/images/P1110885s.jpg)

Here it comes out.

(http://airboxer.com/images/P1110888s.jpg)

The clutch lever gave me a hard time. But after a short fight he gave up.

(http://airboxer.com/images/P1110895s.jpg)

Here is the housing cleaned and ready for paint.

(http://airboxer.com/images/P1110899s.jpg)

And now painted with engine enamel.

(http://airboxer.com/images/P1110902s.jpg)

More pieces to clean and paint.

(http://airboxer.com/images/P1110903s.jpg)

Here it is, ready for assembly.

(http://airboxer.com/images/P1110905s.jpg)

So far so good. I broke the clip ring for the main shaft. Also need to get some other small parts.

(http://airboxer.com/images/P1110912s.jpg)

Hope to be able to assemble it next weekend, and then get back to the heater channels.


Title: Re: My Garage Build - The Airboxer Garage
Post by: rothaus on February 27, 2014, 06:21:14 PM
Time for an update.

Still need to get some of the Transmission parts. In the meantime the heater channel came.

Here a few picture during cutting out careful the old rusted pieces.

(http://airboxer.com/images/P1110916s.jpg)

Laying the whole thing at the side like this makes it so much easier to work on it.
(http://airboxer.com/images/P1110918s.jpg)

Turning it to the position so it's comfortable to work.

(http://airboxer.com/images/P1110923s.jpg)

A section of the old channel is gone, and so some other rusted bits and pieces.

(http://airboxer.com/images/P1110925s.jpg)

Finally, the complete heater channel is out.

(http://airboxer.com/images/P1110927s.jpg)

Now the challenge starts. I sandwiched together the support rail and the heater channel, and the holes do not line up.

(http://airboxer.com/images/P1110931s.jpg)

The rails are made in Germany, the channel is made in Danmark.

(http://airboxer.com/images/P1110933s.jpg)

Looks like I have to do some fitting of these holes, between the channel, rail, and the floor pan.

Also the front end piece I had to flatten out, because it was too short.

(http://airboxer.com/images/P1110934s.jpg)

I put in some bolts between the rail, floor pan and channel, and here goes the first test fit.

(http://airboxer.com/images/P1110937s.jpg)

Some pushing and wiggeling and it actually doesn't fit that bad.

(http://airboxer.com/images/P1110940s.jpg)

Looks like I need to fabricate some pieces to fill in the holes, LOL.

(http://airboxer.com/images/P1110941s.jpg)

Checking the inside, and it doesn't look that bad, as well the measurements of the door opening.

(http://airboxer.com/images/P1110944s.jpg)

On the front side I have to make some pieces. I got the outer skin, but there are some pieces to fabricate. A little more as it was on the right side.

(http://airboxer.com/images/P1110951s.jpg)

Here it is fitted in. Next weekend I will check it out again, mark all the holes which need rework, and if it's all good, tak-weld in the channel.

(http://airboxer.com/images/P1110953s.jpg)

One last look on the RIGHT side, to see some positive things, and then it was time for a nice beer.

(http://airboxer.com/images/P1110946s.jpg)

Cheers
Engelbert


Title: Re: My Garage Build - The Airboxer Garage
Post by: gunny on February 27, 2014, 06:45:51 PM
can you powder coat my rims?

flat black!


Title: Re: My Garage Build - The Airboxer Garage
Post by: rothaus on February 27, 2014, 07:28:22 PM
can you powder coat my rims?

flat black!

The problem is that the oven is not big enough, what are they 18" ?

They need to be bead blasted.


Title: Re: My Garage Build - The Airboxer Garage
Post by: gunny on February 27, 2014, 07:35:25 PM
fronts 18's rear 19's
I think you need to build a bigger box! and one of those bead blasters!

:)

Gunny


Title: Re: My Garage Build - The Airboxer Garage
Post by: rothaus on February 27, 2014, 07:49:44 PM
I got the blasting cabinet 4ft wide.

(http://airboxer.com/images/blast021.jpg)

You must have missed that post.

A large coating oven is on the list. I plan to coat all suspension pieces from the 1970 911, my next project.

(http://airboxer.com/images/70-P1110636s.jpg)


Title: Re: My Garage Build - The Airboxer Garage
Post by: rothaus on March 03, 2014, 03:55:22 PM
Here is what I did last weekend.

Line up of all the holes between the support rail, the heater channel and the floor pan. This took more time as I have expected.

(http://airboxer.com/images/P1110955s.jpg)

Some of the holes need some grinding

(http://airboxer.com/images/P1110957s.jpg)

(http://airboxer.com/images/P1110960s.jpg)

Finally they all fit.

(http://airboxer.com/images/P1110961s.jpg)

Starting on the inside to weld in small pieces where I had to cut of the rusted part.

(http://airboxer.com/images/P1110964s.jpg)

(http://airboxer.com/images/P1110965s.jpg)

Here after it's welded in, the seam at the bottom get's welded together with the support rail.

(http://airboxer.com/images/P1110966s.jpg)

A view from the outside, more holes to close.

(http://airboxer.com/images/P1110969s.jpg)

Fabricating and welding in the new pieces.

(http://airboxer.com/images/P1110971s.jpg)

Here it is welded in.

(http://airboxer.com/images/P1110974s.jpg)

More small pieces welded in. Next is the outside.

(http://airboxer.com/images/P1110977s.jpg)

The last hole between inside and outside is now closed.

(http://airboxer.com/images/P1110979s.jpg)

I found that the piece which goes under the section, is available, so I ordered that. Saves some cutting, bending and hammering.

More next weekend.

Cheers
Engelbert


Title: Re: My Garage Build - The Airboxer Garage
Post by: catapultkid on March 03, 2014, 07:19:01 PM
Looks good, I know that stuff can be so time consuming. Looking forward to the mentioned 911 project...


Title: Re: My Garage Build - The Airboxer Garage
Post by: rothaus on March 12, 2014, 05:38:38 PM
I made some progress the last weekend.

Fitting in the bottom section of quarter panel, and the bottom piece.

(http://airboxer.com/images/P1120010s.jpg)

(http://airboxer.com/images/P1120015s.jpg)

A little cutting bending and grinding and it will fit.

(http://airboxer.com/images/P1120016s.jpg)

Looks a bit ugly, but once it's cleaned up, it will be OK.

(http://airboxer.com/images/P1120019s.jpg)

More welding and grinding.

(http://airboxer.com/images/P1120027s.jpg)

(http://airboxer.com/images/P1120030s.jpg)

This part of the heater channel just did not line up.

(http://airboxer.com/images/P1120035s.jpg)

I decided to cut of the section.
At least the holes from the support rail line up OK.

(http://airboxer.com/images/P1120037s.jpg)

Quite a few pieces to fabricate here for this section, a little more than on the right side.

(http://airboxer.com/images/P1120038s.jpg)

I thought it's a good idea to insert the heating tube now.

(http://airboxer.com/images/P1120041s.jpg)

I found that the new aluminum tubes are larger then the original once. I used a good piece of the old one and they fit nice inside of the new one and it made a nice fit. I will save the rest of the old one, you never know.

(http://airboxer.com/images/P1120039s.jpg)

The heater channel and support rail is now complete welded in.

(http://airboxer.com/images/P1120045s.jpg)

(http://airboxer.com/images/P1120046s.jpg)

Also the rear section is complete, at least from this angle.

(http://airboxer.com/images/P1120056s.jpg)

I found some sections at the inside which I need to cut out and make some new pieces and weld in.

More for next weekend.

Cheers
Engelbert


Title: Re: My Garage Build - The Airboxer Garage
Post by: rothaus on March 16, 2014, 05:27:06 PM
Made no progress on the body work, on the Beetle.

I hade to make some last minute changes on the Tire strategy for the green Car.

Switched to Plan "B" for breit.

I picked up a set of Borbet Felgen last year 7.5 and 9 x 16.

Before

(http://airboxer.com/images/P1120063s.jpg)

After treatment

(http://airboxer.com/images/P1120072s.jpg)

Now I need to get the A6 mounted, and hope I can fit it under the fenders.

The bad thing id that these puppies are heavier and I have more unsprung weight (oder ungefederte Masse), plus the car is now much more heavy. I also need to start from scratch how to drive the thing.

The good thing is that these are taller and my 2nd gear goes further, and I have the same rubber like the Street Prepared cars.

Back to the Garage: One other thing what bugged me was the temperature control for the coating oven. I had to watch the damn thing all the time.

So I did some enhancements. Added a PID digital controller, a better thermocouple, and Solid state relay.

(http://airboxer.com/images/P1110998s.jpg)

(http://airboxer.com/images/P1120081s.jpg)

I had to modify the back channel to make some place for the PID.

(http://airboxer.com/images/P1120001s.jpg)

Now the oven keeps the temperature within 2 Deg F.

To test the new control I coated a few pieces for the transmission.

(http://airboxer.com/images/P1120083s.jpg)

I got some of the missing parts for the Tranny of the beetle, so it's back together, and installed in the chassis.

(http://airboxer.com/images/P1120084s.jpg)

Other then that, I just took the 911 out for a ride, made over 60 miles, just to make sure all the spider webs are out.

Finally got around to replace the master and slave clutch cylinder for the 944 beater, so I have my daily driver back.

Cheers
Engelbert






Title: Re: My Garage Build - The Airboxer Garage
Post by: rothaus on March 27, 2014, 05:37:49 PM
Time for an update. Not so much done, since I hade to get the green machine ready for the first AX next Sunday.

I gave the drive shaft hardware a treatment.

Here is what it looked like after getting all the dirt and grease off.

(http://airboxer.com/images/P1110857s.jpg)

I was not happy with the socket heads, somebody must have used a vicegrip or something like that.

(http://airboxer.com/images/P1110993s.jpg)

So I cleaned them up a little.

(http://airboxer.com/images/P1110997s.jpg)

(http://airboxer.com/images/P1110995s.jpg)

Next Bead blasting and send out for yellowzinc plating

(http://airboxer.com/images/P1120007s.jpg)

Here is what they look like when they came back.

(http://airboxer.com/images/P1120162s.jpg)

Next weekend will not much happen at the VW, sine I take the green car out and see how the new wheels and tires work.

Cheers
Engelbert


Title: Re: My Garage Build - The Airboxer Garage
Post by: rothaus on June 15, 2014, 06:49:47 PM
Looks like it's time for some updates. Not much time for the cars and the garage this spring. It was time to do the front yard.

Here is what it looked before.

(http://airboxer.com/images/House-front01.jpg)

I used up about 80 80# Sackrete, countless painkiller, not to mention the beer.

In process

(http://airboxer.com/images/House-front04.jpg)

And done

(http://airboxer.com/images/House-front02.jpg)

(http://airboxer.com/images/House-front03.jpg)

Cheers
Engelbert


Title: Re: My Garage Build - The Airboxer Garage
Post by: rothaus on June 16, 2014, 06:02:37 PM
OK, I picked up a short term project, at least that what I hope for.

A 87 911 Cab

(http://airboxer.com/images/P1120265s.jpg)

One more

(http://airboxer.com/images/P1120231s.jpg)

The car was sitting for a while so I had to check a few things. Gas tank looks OK. I took out the gas level sender, to check what's going on in the gas tank. To my surprise it was pretty clean.
(http://airboxer.com/images/87_tankgeber01.jpg)


I didn't had much time so I changed the oil and filter. Removed the fuel filter and flushed the fuel lines.

The fuel pump wouldn't run, checked the DME relay, relay Ok, but no ground to switch the fuel pump coil. Bridged for now, black/white cable to ground.

After flushing the fuel line, checked for spark, no spark. Removed and opened the DME, cleaned it and looked for bad solder, all looked good.

(http://airboxer.com/images/32_DME02.jpg)


Checked all DME pins for the correct readings, and all looked OK based on the manual.

Replaced the ignition coil with a 944 spare (which should be OK for the 3.2) No spark. I also checked the spare coil in the 944 and it worked, so not the coil.

Since I had still some time left, I started to rip out the carpet. The best would be just replace the complete, however, I will se what it looks like once it cleaned. The section up on the rear shelf, below the rear window, is heavy faded. I was thinking to replace it with vinyl instead.

(http://airboxer.com/images/P1120366s.jpg)

(http://airboxer.com/images/P1120367s.jpg)

(http://airboxer.com/images/P1120368s.jpg)

Anyway, after messing around with the 944 and some other stuff, I took out the polisher and the 3m compound and gave it a rub.

Here some pictures after:

(http://airboxer.com/images/P1120394s.jpg)

(http://airboxer.com/images/P1120398s.jpg)

More to come

Cheers
Engelbert











Title: Re: My Garage Build - The Airboxer Garage
Post by: rothaus on June 22, 2014, 05:48:19 PM
Well, I got the DME and put it in and the car started right up.

Here is the video

Waking up a 87 911 - YouTube (https://www.youtube.com/watch?v=auK3UYklNWA)


Cheers
Engelbert


Title: Re: My Garage Build - The Airboxer Garage
Post by: whiteryder on June 22, 2014, 07:59:25 PM
Well, I got the DME and put it in and the car started right up.

Here is the video

Try https://www.youtube.com/watch?v=auK3UYklNWA if the prev link doesn't work.


p.s. I think your camera needs a little better bass response to get the full effect!   :)


Title: Re: My Garage Build - The Airboxer Garage
Post by: rothaus on June 23, 2014, 05:33:26 PM
So now that the engine is OK, I did a compression test and LD test

Compr. - LD test
Cyl - Bar - %
1 - 13 - 4
2 - 12.5 - 5
3 - 12.8 - 5
4 - 12.4 - 8
5 - 12.7 - 10
6 - 12.8 - 5

That is not bad at all, from what I expected from that car.

I also took the boroscope and checked out the area under the cooling air shroud. It all looked clean.


(http://airboxer.com/images/2014-06-20-boro.jpg)

Now about the oil leaks. Looks like the most issue are the oil return tubes.

So I decided to take off the complete exhaust, since all the bolts and nuts looked not too bad.

(http://airboxer.com/images/2014-06-20-exhaust01.jpg)

So far so good, just most of the bolts just broke, no big deal, as long the come out.

(http://airboxer.com/images/2014-06-20-exhaust02.jpg)

Not so good with the studs for the heat exchanger.

(http://airboxer.com/images/2014-06-20-exhaust03.jpg)

(http://airboxer.com/images/2014-06-20-exhaust04.jpg)

(http://airboxer.com/images/2014-06-20-exhaust05.jpg)

Got to drill them out.

(http://airboxer.com/images/2014-06-20-exhaust06.jpg)

I do it in small steps.

(http://airboxer.com/images/2014-06-20-exhaust07.jpg)

One done, 3 more to go.

(http://airboxer.com/images/2014-06-20-exhaust08.jpg)

So after the exhaust is out of the way and the studs all drilled out, it's cleaning time.

(http://airboxer.com/images/87_motor01.jpg)

After cleaning it was clear that the oil return tube are the issue. The O-rings are flat.

(http://airboxer.com/images/oil_line01.jpg)

More to come.

Cheers
Engelbert


Title: Re: My Garage Build - The Airboxer Garage
Post by: rothaus on July 07, 2014, 05:58:52 PM
Made some progress on my short term project:

Disassembled the front suspension.

(http://airboxer.com/images/P1120446s.jpg)


Looks like we have some oil leaking going on around the oil cooler.

(http://airboxer.com/images/P1120449s.jpg)

Scraping off the rough stuff

(http://airboxer.com/images/P1120450s.jpg)

(http://airboxer.com/images/P1120451s.jpg)

Front stuff is out

(http://airboxer.com/images/P1120461s.jpg)

(http://airboxer.com/images/P1120463s.jpg)

(http://airboxer.com/images/P1120466s.jpg)

Top in the picture still the old original BOGE

Bottom with the new Bilstein Sport

(http://airboxer.com/images/P1120467s.jpg)

Here all ready for assembly.

(http://airboxer.com/images/P1120468s.jpg)

The protective shields were missing, so I got 2 new once.

(http://airboxer.com/images/P1120469s.jpg)

Still waiting for the new bushings to assemble the A-Arms.

(http://airboxer.com/images/P1120470s.jpg)

The A-Arm Retaining plates were a little beat up. This is the left one which I need to replace, it's twisted and the hook all bent. Let me know if you have a good one floating around.

(http://airboxer.com/images/P1120475s.jpg)

The right one was a little bent, but I could get it fixed and powder coated it.

(http://airboxer.com/images/P1120476s.jpg)

Talking about powder coating... never had a set of powder coated valve covers

Prepping them with Beadtblasting

(http://airboxer.com/images/P1120472s.jpg)

And here it is.

(http://airboxer.com/images/P1120479s.jpg)

The bottom as well, installed after the valve clearance adjusted, also the new oil return tubes are now installed.

(http://airboxer.com/images/P1120483s.jpg)

Removing the old front wheel bearings. Wait when I got the hubs washed and blasted.

(http://airboxer.com/images/P1120481s.jpg)

The weekend is almost over, but the rear shocks are installed.

(http://airboxer.com/images/P1120486s.jpg)

Then it was time for a beer.

More to come.

Cheers
Engelbert


Title: Re: My Garage Build - The Airboxer Garage
Post by: rothaus on July 21, 2014, 05:52:38 PM
Made some progress last weekend.

Installed the new oil return tubes.

(http://airboxer.com/images/P1120511s.jpg)

Blasted the heat exchangers cross-over pipe and the cat.

Heat Exchanger after blasting

(http://airboxer.com/images/P1120489s.jpg)

After painting with VHT Flameproof silver

(http://airboxer.com/images/P1120487s.jpg)

You have to bake the paint at 200F, 400F, and 600F for 30 min, and let it cool for 30 min in between.

My stove actually made it to 600F

(http://airboxer.com/images/P1120506s.jpg)

Here is the setup ready for installation

(http://airboxer.com/images/P1120512s.jpg)

And here installed with all new nuts.

(http://airboxer.com/images/P1120513s.jpg)

(http://airboxer.com/images/P1120520s.jpg)

(http://airboxer.com/images/P1120538s.jpg)

Moving back to the front suspension, hubs are all cleaned up and ready for assembly.

(http://airboxer.com/images/P1120494s.jpg)

New rotors installed and ready for the bearings.

(http://airboxer.com/images/P1120502s.jpg)

Front calipers are blasted. I just left the pistons and dust covers on for blasting. I removed the bleed valve and pluged the hole with an M8 bolt, and taped the hard line, to keep the media out.

(http://airboxer.com/images/P1120495s.jpg)

Here they are, cleaned, coated, and ready for assembly.

(http://airboxer.com/images/P1120508s.jpg)

A few more pieces to poader coat.

(http://airboxer.com/images/P1120507s.jpg)

Assembling the front end.

(http://airboxer.com/images/P1120523s.jpg)

here is the before picture

(http://airboxer.com/images/P1120461s.jpg)

Here it is coming together

(http://airboxer.com/images/P1120528s.jpg)

The only missing thing in this picture is the little clip to hold the cable for the brake pad sensor.

After the car was back on the wheels on the front end I started to attack the rear brakes. Got it all apart and new Hand brake shoes installed.

More next weekend.

Cheers
Engelbert


Title: Re: My Garage Build - The Airboxer Garage
Post by: rothaus on July 27, 2014, 06:31:04 PM
Here is what I did this weekend.

Got the rear caliper cleaned blasted, cleaned again, coated, rebuild, etc.

The Hardware black powder coated as well.

(http://airboxer.com/images/P1120540s.jpg)

Somebody installed some stainless brake lines which did not fit, and some hardware was missing.

(http://airboxer.com/images/P1120539s.jpg)

So I got new once and also the herd lines to the caliper, since I couldn't get them removed without screwing them up.

(http://airboxer.com/images/P1120541s.jpg)

Installed all the good stuff, and it looks good.... at least to me

(http://airboxer.com/images/P1120544s.jpg)

Next is to replace the Master Cylinder. Not much to show, but scheisse, this is a PITA. I really appreciate my '71. You take the cover plate off and there it is

Anyway, now to get all that air out of the system, the brake system.

I always used my Vacuum pump.

(http://airboxer.com/images/P1120552s.jpg)

It's not doing the job. What the hell did I do wrong. Take the MC back out, cleaning up the mess, checking and checking, WTF is going on.

Anyway, me an old German dude doing it the old way, no power whatever. Here in the US everything Power.... Power Bleeder.

No I know why I need a Powa Bleeda

So I'm off to Tractor Supply, get  a sprayer. I found a Brake reservoir cap in my crap, and put a fitting on it, added some vinyl tubing and there I have a powa bleeda.

(http://airboxer.com/images/P1120553s.jpg)

This worked like a champ and all looks good now.

Just one thing, If you do this, block off the little overflow line.

(http://airboxer.com/images/P1120555s.jpg)

Cheers
Engelbert


Title: Re: My Garage Build - The Airboxer Garage
Post by: rothaus on August 17, 2014, 06:21:52 PM
Time for an update, it has being a while.

Since the brakes are now Ok and complete done, I moving the back side of the car.

The bumper was hanging low and the rubber seal was lose.

(http://airboxer.com/images/P1120558s.jpg)

I removed the bumper, tail light, and reflector to clean up the section.

(http://airboxer.com/images/P1120563s.jpg)

The rubber between the bumper and the reas section was OK, but it was ugly. Oileater work great to remove the mess, and make the rubber look like new again.

(http://airboxer.com/images/P1120565s.jpg)

I took that opportunity to take the car out, jack it up and get it cleaned with the power washer... LOL Powa again.

(http://airboxer.com/images/P1120567s.jpg)

Back on the lift and ready to put it all back together.

(http://airboxer.com/images/P1120572s.jpg)

(http://airboxer.com/images/P1120579s.jpg)

The tail lights needed some cleaning and the wires got a sleeve.

(http://airboxer.com/images/P1120583s.jpg)

(http://airboxer.com/images/P1120584s.jpg)


The tail lights lenses had the black paint peeling off.

(http://airboxer.com/images/P1120560s.jpg)

I cleaned them and re-painted the black.

(http://airboxer.com/images/P1120586s.jpg)

It's coming together, the bumper adjusted.

(http://airboxer.com/images/P1120587s.jpg)

Bumperettes (or Stostangenhoerner) are on.

(http://airboxer.com/images/P1120591s.jpg)

The license plate light were also junk, so here the new once.

(http://airboxer.com/images/P1120592s.jpg)

Next, the grill. Somebody must have put some Duck tape on it.

Removed the condenser and grill, and cleaned it all up.Goof-off did the trick with the duck tape glue with out desolving the plastic.

(http://airboxer.com/images/P1120594s.jpg)

The rear end is back together.

(http://airboxer.com/images/P1120599s.jpg)

It' time to move to the next task, and move the car over to the other garage, since I need the lift for other stuff.

Since the car was out and parked next to the older brother, the SC, picture time. Black and White.

(http://airboxer.com/images/P1120603s.jpg)

Next task is to remove the Cabrio top. I have never done a top, so this will be some learning.

I also decided to put the 993 top on it, to make it even more complicated.

(http://airboxer.com/images/P1120604s.jpg)

Things look pretty ugly.

(http://airboxer.com/images/P1120606s.jpg)

OK, lets do it, things come apart.

(http://airboxer.com/images/P1120614s.jpg)

Drilling out the rivets from the seals.

(http://airboxer.com/images/P1120621s.jpg)

Hi -tec support

(http://airboxer.com/images/P1120629s.jpg)

This is almost like Overhauln just this is a one man show.

(http://airboxer.com/images/P1120642s.jpg)

Here we go, the top is gone.

(http://airboxer.com/images/P1120644s.jpg)

Removing the old glue is a PITA. I found that quick peel works great, after spraying it on and let sit for a few minutes.

(http://airboxer.com/images/P1120646s.jpg)

Disassembling the rear section of the top.

(http://airboxer.com/images/P1120660s.jpg)

More glue to remove... I hate this.

(http://airboxer.com/images/P1120669s.jpg)

After cleaning the inside, after removing the old carpet and insulation, I painted it.

(http://airboxer.com/images/P1120671s.jpg)

Time to put in the sound insulation.

(http://airboxer.com/images/P1120693s.jpg)

I used rattle trap. Really good to work with.

(http://airboxer.com/images/P1120702s.jpg)

(http://airboxer.com/images/P1120704s.jpg)

OK, back to the top for a little bit.

(http://airboxer.com/images/P1120708s.jpg)

Putting new foam and vinyl on the rear bow.

(http://airboxer.com/images/P1120710s.jpg)

Here is it done, just need to punch it the 3 holes for the bolts.

(http://airboxer.com/images/P1120714s.jpg)

Next, sorting out the new carpet.

(http://airboxer.com/images/P1120712s.jpg)

It's Sunday late afternoon and time for a beer.

More next weekend.

Cheers
Engelbert


Title: Re: My Garage Build - The Airboxer Garage
Post by: rothaus on September 08, 2014, 06:51:50 PM
OK, It's about time for an update.

Started with the carpet. First the rear shelf section. The original panels were pretty bad, and all warped, so I decided to make some new ones.

(http://airboxer.com/images/P1120724s.jpg)

I used some heavy canvas instead the original black paper to connect the vertical and horizontal section.

(http://airboxer.com/images/P1120727s.jpg)

Staple it all on.

(http://airboxer.com/images/P1120729s.jpg)

Next Recover the 2 small pieces left and right behind the B-Pillar.

(http://airboxer.com/images/P1120711s.jpg)

(http://airboxer.com/images/P1120732s.jpg)

Continue with the new carpet.

(http://airboxer.com/images/P1120730s.jpg)

And some new vinyl pieces left and right

(http://airboxer.com/images/P1120731s.jpg)

(http://airboxer.com/images/P1120734s.jpg)

More new carpet

(http://airboxer.com/images/P1120742s.jpg)

Now the floor boards need some attention.

(http://airboxer.com/images/P1120745s.jpg)

Why always replace if it can be repaired. Now I know why I have a scrollsaw.

(http://airboxer.com/images/P1120743s.jpg)

All glued together and ready to install

(http://airboxer.com/images/P1120744s.jpg)

Now it's time to attack the seats

(http://airboxer.com/images/P1120768s.jpg)

Removing all the power stuff

(http://airboxer.com/images/P1120784s.jpg)

(http://airboxer.com/images/P1120789s.jpg)

Separating the back. There is a square pin that need to be pulled out, after the little socket head screw is removed.

(http://airboxer.com/images/P1120855s.jpg)

(http://airboxer.com/images/P1120857s.jpg)

Removing the old cover, or what is left.. LOL.

(http://airboxer.com/images/P1120799s.jpg)

Some hidden hog rings need to be removed. Always take plenty pictures.

(http://airboxer.com/images/P1120802s.jpg)

And off comes the skin.

(http://airboxer.com/images/P1120807s.jpg)

Next the bottom section.

(http://airboxer.com/images/P1120815s.jpg)

(http://airboxer.com/images/P1120822s.jpg)

The foam of these seats were in good shape and I didn't need to replace any pieces.

(http://airboxer.com/images/P1120832s.jpg)

Replacing the overlay of the side sections.

(http://airboxer.com/images/P1120833s.jpg)

And putting it back together.

(http://airboxer.com/images/P1120835s.jpg)

And here they are all new leather. The still have some wrinkles, but with a bit steam it will be fine.

(http://airboxer.com/images/P1120887s.jpg)

More to come.

Cheers
Engelbert


Title: Re: My Garage Build - The Airboxer Garage
Post by: ccann26 on September 09, 2014, 03:19:20 PM
You are a magician.


Title: Re: My Garage Build - The Airboxer Garage
Post by: rothaus on September 11, 2014, 05:43:14 PM
More progress.

Now it's time to work on the door panels.

(http://airboxer.com/images/P1120888s.jpg)

They are not so bad, but I need to see what's going on behind them.

The left mirror was also just hanging lose on the cables.

(http://airboxer.com/images/P1120905s.jpg)

On the workbench for surgery.

(http://airboxer.com/images/P1120918s.jpg)

I found that the bolt where the cable go thru was lose.

(http://airboxer.com/images/P1120917s.jpg)

With the cables in the way the bold cannot be screwed in and tightening.

(http://airboxer.com/images/P1120916s.jpg)

So I had to remove all the pins from the socket, to get the cable out.

(http://airboxer.com/images/P1120912s.jpg)

Now the bolt can go back in.

(http://airboxer.com/images/P1120913s.jpg)

Next the cable and put it all back together.

(http://airboxer.com/images/P1120914s.jpg)

Tested the mirror and switch and it's all working. :)

More for the coming weekend.

Cheers
Engelbert


Title: Re: My Garage Build - The Airboxer Garage
Post by: rothaus on September 18, 2014, 06:01:06 PM
A little update:

Installed the new headliner.

(http://airboxer.com/images/P1120926s.jpg)

I got the 993 top made vor the 911 and 964

(http://airboxer.com/images/P1120932s.jpg)

This looks much better and it actually fits.

(http://airboxer.com/images/P1120933s.jpg)

I had to replace the tension cables on both sides, there is a left and right side.

(http://airboxer.com/images/P1120935s.jpg)

The old once were all messed up.

(http://airboxer.com/images/P1120937s.jpg)

Here installed.

(http://airboxer.com/images/P1120938s.jpg)

Looks almost real

(http://airboxer.com/images/P1120941s.jpg)

Some pieces to be recovered with new vinyl.

(http://airboxer.com/images/P1120942s.jpg)

The carpet is also installed now, and it looks almost like a car again.

(http://airboxer.com/images/P1120949s.jpg)

Sorting the cables for the new stereo.

(http://airboxer.com/images/P1120953s.jpg)

The seats are in and I can actually sit in the car. :D

(http://airboxer.com/images/P1120955s.jpg)

Next are the door panels. Somebody installed large speakers and tweeter, and made some big holes. Not sure yet how to deal with these holes, without to recover the panels, which actually look OK.

Something to figure out.

More next week.

Cheers
Engelbert


Title: Re: My Garage Build - The Airboxer Garage
Post by: whiteryder on September 18, 2014, 07:17:41 PM

Beautiful.  Love watching it all come together.

I don't know what sort of animal would fit in those back seats though!


Title: Re: My Garage Build - The Airboxer Garage
Post by: rothaus on September 19, 2014, 05:10:05 PM
No animal in this car. The rear seats are still missing, haha.

Cheers
Engelbert


Title: Re: My Garage Build - The Airboxer Garage
Post by: wahoo5 on September 19, 2014, 07:00:34 PM
Very nice. Is this to drive or to sell? It is amazing how the prices of the older 911s are going through the roof.

David


Title: Re: My Garage Build - The Airboxer Garage
Post by: rothaus on September 25, 2014, 06:28:16 PM
Very nice. Is this to drive or to sell? It is amazing how the prices of the older 911s are going through the roof.

David

For sure driving it, not sure yet about selling yet.


Cheers
Engelbert


Title: Re: My Garage Build - The Airboxer Garage
Post by: rothaus on September 25, 2014, 06:29:17 PM
OK, here is what I did with the gauges.

They didn't look like new, so I need to do something.

(http://airboxer.com/images/P1120970s.jpg)

I removed the Tank and Oil level gauge and took a look what can be done.

(http://airboxer.com/images/P1120975s.jpg)

The rings were actually rusted, so I took it apart so see if I can remove the rust and paint them.

The inside of the gauge was actually nice clean and in good condition.

(http://airboxer.com/images/P1120977s.jpg)

I went and started to clean up the rings with the dremmel sander, and they came out OK.

(http://airboxer.com/images/P1120979s.jpg)

Ready for painting or coating.

But wait a minute, I just don't have the time to mess around with this. I also remembered that I have a set of gauges upstairs.

The only thing I didn't want to replace is the speedo, and the Tach I got is from a SC.

So here we go. Installing the spare Fuel/Oil gauge, with the LED's.

(http://airboxer.com/images/P1120981s.jpg)

What a difference.

(http://airboxer.com/images/P1120982s.jpg)

Next the Oil temp and Druck

(http://airboxer.com/images/P1120984s.jpg)

The tach and the speedo I just cleaned as good as possible and put it back in with the new LED's installed.

(http://airboxer.com/images/P1120989s.jpg)

Last but not least the clock.

(http://airboxer.com/images/P1120990s.jpg)

Here a picture with all back in.

(http://airboxer.com/images/P1120993s.jpg)

The next thing to fix, was a broken log from the steering column cover.

(http://airboxer.com/images/P1120994s.jpg)

After cleaning and some superglue, it's ready to go back on.

(http://airboxer.com/images/P1120997s.jpg)

The next thing before the steering wheel goes on.

(http://airboxer.com/images/P1120998s.jpg)

Install one of these nice bearings from Mitch Lealand

(http://airboxer.com/images/P1120999s.jpg)

More next weekend.

Cheers
Engelbert




Title: Re: My Garage Build - The Airboxer Garage
Post by: jamescarriv on October 23, 2014, 12:37:20 PM
Have you entered yet?

http://classicmotorsports.net/events/show-us-your-shop/


Title: Re: My Garage Build - The Airboxer Garage
Post by: rothaus on October 23, 2014, 05:28:57 PM
Ja Ja right, forget it, when I look at these picture, there is no way my little garage would have a chance. LOL.

Cheers
Engelbert


Title: Re: My Garage Build - The Airboxer Garage
Post by: rothaus on October 23, 2014, 05:31:12 PM
Drove the Cab around last weekend.

Stopped for some pictures.

(http://airboxer.com/images/87-001.jpg)

(http://airboxer.com/images/87-002.jpg)

(http://airboxer.com/images/87-003.jpg)

Still more things to do.

I have the street tires from the froggy on right now. I have some Cup 1 wheels in the works. Plan to polish the lips and paint the rest black as the car is.

Other then that, I got a few more bugs to work out, and a few more things to finish.

Will post as I get more done.

Cheers
Engelbert


Title: Re: My Garage Build - The Airboxer Garage
Post by: wahoo5 on October 23, 2014, 05:34:01 PM
It is looking good.

David


Title: Re: My Garage Build - The Airboxer Garage
Post by: rothaus on October 27, 2014, 06:16:07 PM
After driving the car over the weekend I got brave and decided to drive to work. Everything was fine. The H4 light are great, the instrument gauges are nice with the LED's, the heat works, the seats are nice, etc.

Parked the car went to work.

In the evening, when I tried to start the car, it fired up for a second and died.

OK, call Claudia to pick me up put the trailer on the Cayenne, load it up, park it. Next day I checked out WTF is going on. Turns out the fuel pump just died. I unplugged the DME relay and bridged from 30 to the 87b and the pump just clicks a bit. I was surprised that the fuse was not blown.

So I got a new fuel pump now, I also ordered a new DME relay as spare and just in case.

The next thing to trouble shoot is the washer fluid pump and the intermitent wiper function.

Still need to do the door panels, I got the vinyl finish stitched, need to make new cards, etc.

Oh, I also found a set of 964 Cup wheels 7 and 9 x 17 which I working on.... will post some pictures soon.

Cheers
Engelbert


Title: Re: My Garage Build - The Airboxer Garage
Post by: rothaus on November 01, 2014, 03:01:36 PM
Little update on the Cab.

Replaced the fuel pump today. Here is what the old one looked like after I took it apart. I want to see what's inside. Nothing was moving, all was stuck.

(http://airboxer.com/images/fuelpump.jpg)

I's back running.

So I made a little progress on the door panels. The old once where actually worse than I expected.

(http://airboxer.com/images/doorcard_001.jpg)

Here is one more picture when I had the vinyl off.

(http://airboxer.com/images/doorcard_002.jpg)

So I decided to make some new once out of 1/4 plywood. I put a clear coat on it so will last better than the cardboard.

(http://airboxer.com/images/doorcard_003.jpg)

(http://airboxer.com/images/doorcard_004.jpg)

Here is the new finish stitched vinyl.

(http://airboxer.com/images/doorcard_005.jpg)

Looks like its a good match to the leather seat.

(http://airboxer.com/images/doorcard_006.jpg)

More next weekend, tomorrow is the last autocross for this year.

Cheers
Engelbert


Title: Re: My Garage Build - The Airboxer Garage
Post by: rothaus on November 13, 2014, 06:37:53 PM
Made some progress on the door panels.

I put a few coats of clear Polyurethane on the plywood.

(http://airboxer.com/images/doorpannels001.jpg)

Here with the new vinyl.

(http://airboxer.com/images/doorpannels002.jpg)

(http://airboxer.com/images/doorpannels003.jpg)

(http://airboxer.com/images/doorpannels004.jpg)

This time the panels are installed with vapor barrier

(http://airboxer.com/images/doorpannels005.jpg)

Here old and new comparison.

(http://airboxer.com/images/doorpannels006.jpg)

And finish installed.

(http://airboxer.com/images/doorpannels007.jpg)

One more picture of the car.

(http://airboxer.com/images/DSCN1195s.jpg)

The car still sits a bit low, but I want to wait until I got the 17" cup wheels ready, and do the final adjustment after that. These are the 15 inch street tires I use when I drive the green car on the street.

Getting close, and the next task is to get back to finish the 78 beetle.

Cheers
Engelbert


Title: Re: My Garage Build - The Airboxer Garage
Post by: wahoo5 on November 13, 2014, 09:14:03 PM
Very nice work. It is really looking good.


Title: Re: My Garage Build - The Airboxer Garage
Post by: whiteryder on November 14, 2014, 05:54:55 AM

Beautiful!!

Is that round thing above the arm rest the door handle?


Title: Re: My Garage Build - The Airboxer Garage
Post by: rothaus on November 14, 2014, 06:43:34 PM

Beautiful!!

Is that round thing above the arm rest the door handle?


This is from the old days without all the electronic Crap things in the cars.

That is for the door lock, since the pin is even with the top panel, and cannot be pulled out, so you just turn the knop.

Here is a video that shows how it work. They just installed a keyless thingy.

https://www.youtube.com/watch?v=PlcD7vmd_Y8 (https://www.youtube.com/watch?v=PlcD7vmd_Y8)

Cheers
Engelbert


Title: Re: My Garage Build - The Airboxer Garage
Post by: rothaus on December 14, 2014, 11:12:15 AM
So the black Cabrio is done (more or less), still need to get the wheels completed and tires mounted.

In the meantime I started to get back on the 78 Beetle. A few more weekends welding, cutting, grinding, etc.

Hope to got all the welding done before end of this year, if nothing else come in the way.

So stay tuned for more...

Cheers
Engelbert


Title: Re: My Garage Build - The Airboxer Garage
Post by: rothaus on December 17, 2014, 06:52:22 PM
I made some progress last weekend, and found more rust. Inside left and right rear section. I just cut out until I hit good material.

(http://airboxer.com/images/VW_2014-12-13_1.jpg)

Clean it all up, and ready for some new sheet metal.

(http://airboxer.com/images/VW_2014-12-13_2.jpg)

(http://airboxer.com/images/VW_2014-12-13_3.jpg)

And one more section done.

(http://airboxer.com/images/VW_2014-12-13_4.jpg)

More to cut out inside the engine compartment

(http://airboxer.com/images/VW_2014-12-13_5.jpg)

(http://airboxer.com/images/VW_2014-12-14_1.jpg)

My plan is to get the welding done by New Year, cross your fingers.:)

More to come.

Cheers
Engelbert


Title: Re: My Garage Build - The Airboxer Garage
Post by: rothaus on January 07, 2015, 06:12:42 PM
I made some progress over the holidays.

Finished the rear inside corners.

(http://airboxer.com/images/VW_2014-12-23_01.jpg)

So now it's time to move to the right rear corner behind the rear wheel section.

(http://airboxer.com/images/VW_2014-12-23_02.jpg)

As more I poke around as more I find.

(http://airboxer.com/images/VW_2014-12-23_03.jpg)

keep cutting until I hit good material.

(http://airboxer.com/images/VW_2014-12-23_04.jpg)

Welding in more pieces.

(http://airboxer.com/images/VW_2014-12-23_05.jpg)

I reused a piece which I cut out, since I had to get under there. It was easier to cut it out and weld back in, instead to fabricate the whole thing.

(http://airboxer.com/images/VW_2014-12-24_01.jpg)

The bottom section I had to make new.

(http://airboxer.com/images/VW_2014-12-24_02.jpg)

With the rear section done, it's time to move to the left front section, where I had to cut out quit some rust.

(http://airboxer.com/images/VW_2014-12-24_03.jpg)

Making more pieces and welding in.

(http://airboxer.com/images/VW_2014-12-26_01.jpg)

One down, a lot more to go.

(http://airboxer.com/images/VW_2014-12-26_02.jpg)

It's coming slowly together

(http://airboxer.com/images/VW_2014-12-26_03.jpg)

Now the outside.

(http://airboxer.com/images/VW_2014-12-26_04.jpg)

And finally the outer skin.

(http://airboxer.com/images/VW_2014-12-27_01.jpg)

The black piece was purchased.

(http://airboxer.com/images/VW_2014-12-27_02.jpg)

Almost done

(http://airboxer.com/images/VW_2014-12-27_03.jpg)

And finally with the rip piece welded in.

(http://airboxer.com/images/VW_2014-12-27_04.jpg)

Now I moved the the dash section. There was also more rust than I wanted, plus the holes from an after marked AC, which looked like cut out by a chainsaw.

(http://airboxer.com/images/VW_2014-12-27_05.jpg)

(http://airboxer.com/images/VW_2014-12-27_06.jpg)

Here a picture of the bad sections cut out.

(http://airboxer.com/images/VW_2014-12-28_01.jpg)

Here are the pieces which need to be replaced.

(http://airboxer.com/images/VW_2014-12-28_02.jpg)

The bottom section welded in.

(http://airboxer.com/images/VW_2014-12-28_03.jpg)

Re-creating the replacement pieces with holes, etc.

(http://airboxer.com/images/VW_2014-12-28_04.jpg)

And ready to be welded in.

(http://airboxer.com/images/VW_2014-12-28_05.jpg)

Done with this on.

(http://airboxer.com/images/VW_2014-12-28_06.jpg)

Now all the bad stuff is cut out. This is not an easy section, all is 3 dimensional.

(http://airboxer.com/images/VW_2015-01-03_01.jpg)

Here a new piece.

(http://airboxer.com/images/VW_2015-01-03_02.jpg)

And the last little piece ready to weld.

(http://airboxer.com/images/VW_2015-01-03_03.jpg)

Here it is, all welded and cleaned up.

(http://airboxer.com/images/VW_2015-01-03_04.jpg)

That was the last section of the body. I still have to do the doors. They got some rust at the bottom section. That will be next.

Cheers
Engelbert


Title: Re: My Garage Build - The Airboxer Garage
Post by: rothaus on February 10, 2015, 07:00:16 PM
I will get to the beetle later, however, here is some update on the Carrera Cab.

Besides that it did really good on the treadmill, it now got new shoes.

(http://airboxer.com/images/1987_Carrera_15-02-07-01.jpg)

(http://airboxer.com/images/1987_Carrera_15-02-07-02.jpg)

A few more things to do, but this turned out to be a great little car.

Cheers
Engelbert


Title: Re: My Garage Build - The Airboxer Garage
Post by: rothaus on April 11, 2015, 07:18:53 PM
I Got some questions how I made the flares for the 911.

Here are some pictures which explain how I did it.

I used styrofoam and bondo for the plug.

(http://airboxer.com/images/flare01.jpg)

(http://airboxer.com/images/flare02.jpg)

OK, here is the next step to complete the plug.

First I taped the Styrofoam before adding Bondo.

(http://airboxer.com/images/flares001.jpg)

(http://airboxer.com/images/flares002.jpg)

Now it get's messy, all this ugly bondo, juck..

(http://airboxer.com/images/flares003.jpg)

More bondo and sanding and more bondo and more sanding, you get the idea, until it looks like I want to.

(http://airboxer.com/images/flares004.jpg)

(http://airboxer.com/images/flares005.jpg)

Now it get ugly again for the molds.

(http://airboxer.com/images/flares006.jpg)

After the molds are done the plugs can come off, and gute nacht to the dump.

(http://airboxer.com/images/flares007.jpg)

OK, so now I have molds.

(http://airboxer.com/images/flares008.jpg)

Now I make the flares.

(http://airboxer.com/images/flares009.jpg)

These flares are just to make space for what I need. These are a lot smaller then turbo or ST flares.

Here are pictures when I test fitted them over the RS rear flares.

(http://airboxer.com/images/flares010.jpg)

(http://airboxer.com/images/flares011.jpg)

Here is a picture of the front flare test fit.

(http://airboxer.com/images/flares012.jpg)

The Front bumper/spoiler need some modification as well.

(http://airboxer.com/images/flares013.jpg)

(http://airboxer.com/images/flares014.jpg)

(http://airboxer.com/images/flares015.jpg)

Here is a picture of the car during the alignment, still with the 16" wheels at the rear end.

(http://airboxer.com/images/flares016.jpg)

Here is the finished product with the 17" wheels at the rear end.

(https://farm9.staticflickr.com/8684/16404747973_57ffaebfdf_b.jpg)

No problem with rubbing like last year.

Cheers
Engelbert


Title: Re: My Garage Build - The Airboxer Garage
Post by: rothaus on April 11, 2015, 07:20:37 PM
After all the grinding and welding, making a mess by making flares for the 911, and all the dust, which goes everywhere, it was time to clean up the mess.

Here are some picture after clean-up. I know, it will not stay for long like that, but I enjoyed it after I was done.

(http://airboxer.com/images/springclean01.jpg)

(http://airboxer.com/images/springclean02.jpg)

(http://airboxer.com/images/springclean03.jpg)

(http://airboxer.com/images/springclean04.jpg)

(http://airboxer.com/images/springclean05.jpg)

Cheers
Engelbert


Title: Re: My Garage Build - The Airboxer Garage
Post by: rothaus on June 30, 2015, 05:42:42 PM
Made some progress on the '70 911.

A few weekends ago I put it on the lift. Removed the engine and transmission.
(http://airboxer.com/images/70_911_engine_01.jpg)

Looks like 45 years of dirt
(http://airboxer.com/images/70_911_engine_02.jpg)

I had some issues with the clutch fork to get out. One of the 3 pins to release the clutch just snapped off.

OK, plan "B", just loosen all bolts which hold the clutch to the flywheel, and take out the transmission with the clutch included. Damn, one of the 12 point socket head bolts just turned round. :bang:

OK, now plan "C" Hammer and chisel. Finally got it out.
(http://airboxer.com/images/70_911_engine_03.jpg)

(http://airboxer.com/images/70_911_engine_04.jpg)


Made some more progress this Sunday.

Removed the doors.
(http://airboxer.com/images/70_911_apart_01.jpg)

(http://airboxer.com/images/70_911_apart_02.jpg)

On the left door one of the bolts was already round, OK, hammer and chisel out again, and out it comes.
(http://airboxer.com/images/70_911_apart_03.jpg)

Removed the seats, and the right seat gave me some issued. one of the bolts that holds the slider to the seat was sticking out. It was the one at the rear left, the place you really can't get to. However, I was able to knock it off with a punch, and pull it out.

Next: the carpet, which turned out to in good shape, and I may reuse it after a good cleaning.
(http://airboxer.com/images/70_911_apart_05.jpg)

The original owner must have really taken good care to the car, the floor boards looked like new.
(http://airboxer.com/images/70_911_apart_04.jpg)

Now, that I have removed all the interior, and the rear shelf sound dampening, I'm wondering if I should remove the section where the rear seats are. There are no signs of any rust from the bottom, and the inside looks really great. I think I will just destroy the pad by removing it, and it will be a waste.
(http://airboxer.com/images/70_911_apart_06.jpg)

Here is a picture of the rear shelf after removing the sound pad
(http://airboxer.com/images/70_911_apart_07.jpg)

Moving to the engine compartment. Wonder why somebody sprayed some red paint there. I will be able to clean it.

(http://airboxer.com/images/70_911_apart_08.jpg)

After removal of all the High tech stuff, I moved to the front.
(http://airboxer.com/images/70_911_apart_09.jpg)

All the ventilation system is now gone. The orriginal silver paint is still there.
(http://airboxer.com/images/70_911_apart_10.jpg)

All the part are packed and labeled.

More next weekend

Cheers
Engelbert


Title: Re: My Garage Build - The Airboxer Garage
Post by: rothaus on July 23, 2015, 07:38:23 PM
Made some progress. All the instruments and the electrical is removed.

The car was blasted and that stuff is every where, good I take it all apart.

(http://airboxer.com/images/P1130644s.jpg)

(http://airboxer.com/images/IMGP0172s.jpg)

The gauges look pretty good, need to test them to make sure they all work correct.
(http://airboxer.com/images/P1130665s.jpg)

I tested the radio, and it's actually working. Just one issue is the indicator needle is not moving with the dial. Need to find somebody who does repairs on these old radios.

(http://airboxer.com/images/P1130671s.jpg)

Here is some material that need to be sorted out and cleaned.

(http://airboxer.com/images/IMGP0192s.jpg)

I took the electrical panel from the engine first.

Before
(http://airboxer.com/images/P1130673s.jpg)

All parts cleaned
(http://airboxer.com/images/P1130692s.jpg)

Done
(http://airboxer.com/images/P1130695s.jpg)

One thing good to go, and I can pack it away and attac the next. It's always nice to complete a small project during a rebuild.

More to come

Cheers
Engelbert


Title: Re: My Garage Build - The Airboxer Garage
Post by: rothaus on August 05, 2015, 04:57:04 PM
I made some progress.

All the suspension parts are removed. Got some parts blasted.

(http://airboxer.com/images/911T1130708s.jpg)

And Powder coated.

(http://airboxer.com/images/911T1130724s.jpg)

(http://airboxer.com/images/911T1130723s.jpg)

(http://airboxer.com/images/911T1130721ss.jpg)

Here the struts and hubs.

(http://airboxer.com/images/911T1130719s.jpg)

The hubs have quite some corrosion, and I think I need to find some good once.

(http://airboxer.com/images/911T1130719ss.jpg)

Here are the struts after blasting. There were Koni insetrts installed. I need to see if it would make sense to rebuild them, or just put a set of Bilstein HD in.

(http://airboxer.com/images/911T1130754s.jpg)

I started to get the undercoat off which was sprayed on the car, what a mess. I got a good tip about using Kerosine. It works but slow, however, that's better than anything else I have tried.

Here are a few sections I cleaned up. I sprayed it on with a spray bottle, and then used a brush to loosen it up, and wiped it off with rags. I put a plastic on the floor and some oil try on it.

(http://airboxer.com/images/911T1130749s.jpg)

It looks like the factory chip guard is light gray.

(http://airboxer.com/images/911T1130732s.jpg)

To be continued

Cheers
Engelbert


Title: Re: My Garage Build - The Airboxer Garage
Post by: wahoo5 on August 06, 2015, 01:18:29 PM
Impressive work as always. Thanks for posting. Your early 911s are becoming quite the 401(k)!

David


Title: Re: My Garage Build - The Airboxer Garage
Post by: rothaus on August 16, 2015, 05:11:01 PM
Have some trouble with the Froggy. Went to the Porschefest last weekend, and the car did not sound, and feel right, and I noticed the loss of HP.

So back home checked a few thinks like the distributor, to make sure I did not loose the belt drive for the second. All OK. Then I put it on the lift and while running I checked the temperature of the exhaust flanges. I found that cyl # 3 is about half the temp compared the the rest. A leak down test showed that there is a leak at the head gasket area.

my first thing was: a head stud again ? When I rebuild the engine I selected to use Supertech studs, which are not supposed to fail.... WTF.

OK, yesterday I will drop the engine to see what's going on, I cannot drive it like that.

Another unplanned thing to slow me down on the 1970 911T. &%#@%$

Yesterday I took the car over to the shop on the lift and did some more checks, before dropping the engine. I torqued the head studs and all looked OK, no loose nuts or pulled head studs. So I did another leak-down test and found the cyl # 2 has a slight leak, I can hear from the cyl/head area, Cyl # 3 heavier.

I took the engine out.

Here is what I found.

Looks like the 3rd cylinder has a leak. The second a bit. Number 1 was all clean.

(http://airboxer.com/images/IMGP0202s.jpg)

Here a closeup of # 3

(http://airboxer.com/images/IMGP0202s2.jpg)

Here are the heads. # 3 is at the left.

(http://airboxer.com/images/IMGP0199s.jpg)

After all the car did OK, here are the unofficial results http://live.axti.me/results/W1aXToZUVl (http://live.axti.me/results/W1aXToZUVl)

Looks like I need to take one of my spare cars next weekend.

Cheers
Engelbert


Title: Re: My Garage Build - The Airboxer Garage
Post by: rothaus on September 10, 2015, 05:30:23 PM
OK, time for an update.

So the car is back together.

Engine come together
(http://airboxer.com/images/2015-3.6-001.jpg)

From the stand on the jack
(http://airboxer.com/images/2015-3.6-002.jpg)

And into the car.
(http://airboxer.com/images/2015-3.6-003.jpg)

I got it running and drove it around over 40 miles and it feels, sound good, and has the power as it had before. This Sunday I go for the last Shenandoah PCA AX in Verona. 

Now it's time to get back at the 1970 911T Project, after a short interruption for the green car.

I made the supports for the rotisserie.

I'm using the engine stands I used for the beetle.
Front
(http://airboxer.com/images/911_rostiserie-01.jpg)

Rear
(http://airboxer.com/images/911_rostiserie-02.jpg)

And here connected to the stand.
(http://airboxer.com/images/911_rostiserie-03.jpg)

(http://airboxer.com/images/911_rostiserie-04.jpg)

And here up on the grill
(http://airboxer.com/images/911_rostiserie-05.jpg)

And flipped to the side.
(http://airboxer.com/images/911_rostiserie-06.jpg)

And here you can see that crap I still have to remove, but having the car in this position will make it a bit easier, if that is even possible.
(http://airboxer.com/images/Under_shit.jpg)

So now that I can easy look into the hole, I found a little surprise, which I don't like.
(http://airboxer.com/images/T_Tube-01.jpg)

At the section where the bushing sits, is the ring at the bottom section rusted away.
(http://airboxer.com/images/T_Tube-02.jpg)

I cleaned it up a bit and found that the rin is still sold, but has some pitting. The rest of the tube is very solid and has just some surface rust.
(http://airboxer.com/images/T_Tube-03.jpg)

I'm thinking about to grind out that piece and make a sleeve with the ring, which is the stop point for the bushing. Once I have it out, I should see if the outer sleeve part is actually welded on the inside, which I don't think. I think it's only inserted and welded around the outside.

This weekend I will make an attempt to get that black crap of the floor. If anyone want to come by and help, I got plenty of kerosene.

Cheers
Engelbert


Title: Re: My Garage Build - The Airboxer Garage
Post by: jloehlein on September 10, 2015, 05:51:47 PM
I like the rotisserie.  How much you think the shell weighs?


Title: Re: My Garage Build - The Airboxer Garage
Post by: rothaus on September 10, 2015, 06:13:42 PM
I like the rotisserie.  How much you think the shell weighs?

That should be around 640 #

Would be good to know what it is exactly.

Cheers
Engelbert


Title: Re: My Garage Build - The Airboxer Garage
Post by: rothaus on September 14, 2015, 05:31:29 PM
OK, I get most of this stuff off.

Here is partial success
(http://airboxer.com/images/undercrap01.jpg)

I got the stuff off. This is like some paint over spray.
(http://airboxer.com/images/undercrap02.jpg)

Here the rear end.
(http://airboxer.com/images/undercrap03.jpg)

It's amazing what can be found once the black crap is removed, the blank metal. :bang:
(http://airboxer.com/images/undercrap04.jpg)

There is a lot of grinding and re-welding needed to get this right.

This is what I found after cleaning off the black stuff. This is the inside of the left side of the door lock post.
(http://airboxer.com/images/undercrap05.jpg)

So much for that.

I made some dollies, so I can roll it around.
(http://airboxer.com/images/dolly01.jpg)

(http://airboxer.com/images/dolly02.jpg)

(http://airboxer.com/images/dolly03.jpg)

(http://airboxer.com/images/dolly04.jpg)

Cheers
Engelbert


Title: Re: My Garage Build - The Airboxer Garage
Post by: rothaus on November 19, 2015, 05:31:27 PM
I made some progress.

Started on the welds of the front suspension pan. Where the new pan connects to the old piece it was overlapped about 2.5" and welded on both sides.

(http://airboxer.com/images/70suspan01.jpg)

(http://airboxer.com/images/70suspan02.jpg)

I started careful to grind of the bottom layer. It already had some surface rust in between.

(http://airboxer.com/images/70suspan03.jpg)

I was able to clean it up and re-weld as needed.

(http://airboxer.com/images/70suspan04.jpg)

From the inside, and more welds to grind, re-weld and grind.

(http://airboxer.com/images/70suspan05.jpg)

Here partial done.

(http://airboxer.com/images/70suspan06.jpg)

And here after I got it all cleaned up, and a coat of POR15. Next some primer and seal sealer, and after that the Chip Guard, or goes the chip guard first and then the primer ??

(http://airboxer.com/images/70suspan07.jpg)

Moving to the Rockers. I was not sure what's under the lead filler, so I decided to remove it.
Another find I didn't like to see.

(http://airboxer.com/images/70rocker01.jpg)

Basically the same thing on the other side. The door posts were replaced and the overlap from the quarter panel is very thin and has some holes. Also it is dented in at the rocker section.

(http://airboxer.com/images/70rocker02.jpg)

At the left side some repairs were done to rocker support. It must have being pounded in with a hammer or so.

(http://airboxer.com/images/70rocker03.jpg)

I'm thinking to get a new section for the left and right side for the quarter panel. there is a 6" section available, and once open, I can also replace the rocker support.

So now I move to the rear end of the car, and see what damage I can do. The back section of the right quarter panel was replace replaced. And I being told that that was done, when the original owner picked up the car new in Stuttgart, and had an accident.

The section is already pulled in a bit, and I will need some lead to fill it, but I also re-welded and cleaned it up a bit.

(http://airboxer.com/images/70rear01.jpg)

More good news. I started to poke around at the left section where the quarter panel meets the back section, and found quite some body filler.

(http://airboxer.com/images/70rear02.jpg)

After getting rid of all the body filler, I was surprised that it was in good shape, no rust, just ugly. But if don't remove the filler, you don't know what's under it.

(http://airboxer.com/images/70rear03.jpg)

(http://airboxer.com/images/70rear04.jpg)

The other side looks pretty good.

(http://airboxer.com/images/70rear05.jpg)

So now I will get those pieces, before I start cutting.

I'm now a bit more behind as I wish, I was hoping to get soon to the point for Painting, but now this may will not happen before the end of this year.

Cheers
Engelbert


Title: Re: My Garage Build - The Airboxer Garage
Post by: rothaus on December 04, 2015, 05:41:05 PM
OK, here a little update.

I got the 2 pieces for the front of the rear quarter panels, and the rocker support pieces. In the meantime I did a few small things.

Since I removed some body filler at the right side of the quarter panel is welded by the engine compartment, I thought it would be good to see how the rear lid fits.
(http://airboxer.com/images/70rear06.jpg)

Not too bad at the left

(http://airboxer.com/images/70rear07.jpg)

And here at the right.

(http://airboxer.com/images/70rear08.jpg)

Still, need some fine tuning.

Next I attacked the section in the trosion bar hole. I decided not to cut out the sleeve, since it's pretty solid.

(http://airboxer.com/images/torsion_hole_01.jpg)

I made some pieces to weld in.

(http://airboxer.com/images/torsion_hole_02.jpg)

And here it is after welding and cleaning up a bit.

(http://airboxer.com/images/torsion_hole_03.jpg)

Now I moved to some smaller projects, the heater flaps were asking for an overhaul.

(http://airboxer.com/images/Heat-flap_01.jpg)

I disassembled them and cleaned and blasted them.

(http://airboxer.com/images/Heat-flap_02.jpg)

And powder coated them

(http://airboxer.com/images/Heat-flap_03.jpg)

And here they are assembled, just need to find new springs, either plated or SS.

(http://airboxer.com/images/Heat-flap_04.jpg)

The coming weekend I plan to attack the rear quarter panels and fit the new pieces in. Hope for not too many surprises.

Cheers
Engelbert


Title: Re: My Garage Build - The Airboxer Garage
Post by: rothaus on December 19, 2015, 03:56:40 PM
OK, I made some progress.

Here is a picture of the new sheet metal piece.

(http://airboxer.com/images/rightsection001.jpg)

I cut out a piece which will be replaced anyway, to see what's under it.

(http://airboxer.com/images/rightsection002.jpg)

A lot of caulking in there. Also there was some rust in the area of the jack support.

(http://airboxer.com/images/rightsection003.jpg)

Once I had removed the caulking where the rockers are welded, or should I say "where they supposed to be welded on". It looks like they were put on for decoration.

(http://airboxer.com/images/rightsection004.jpg)

OK, lets cut out some pieces, and make it right.

(http://airboxer.com/images/rightsection005.jpg)

Once the rocker was off, it dind't look that bad.

(http://airboxer.com/images/rightsection006.jpg)

The same thing with the inner rocker panel.

(http://airboxer.com/images/rightsection007.jpg)

After removing the inner rocker panel, I found that the heat tube was a bit damaged, but not bad. they must have cut in a bit when the old sheet metal was removed. And then fixed it wit good old duck tape. :bang:

(http://airboxer.com/images/rightsection008.jpg)

It's just amazing what you can find. This little mouse must have moved it years ago and could not found any food, and died.

(http://airboxer.com/images/rightsection009.jpg)

So here are the removed pieces. I will clean them up and reuse.

(http://airboxer.com/images/rightsection010.jpg)

After all it doesn't look that bad.

(http://airboxer.com/images/rightsection011.jpg)

Now I have to attack the areas which need some metal replaced.

(http://airboxer.com/images/rightsection012.jpg)

Cutting out the bad.

(http://airboxer.com/images/rightsection013.jpg)

I'm glad I also ordered new rocket support pieces.

(http://airboxer.com/images/rightsection014.jpg)

After cutting out the supports which were welded in like the rockers, I found some morerust under it. OK, more to cut out and weld.

(http://airboxer.com/images/rightsection015.jpg)

Prepped for the new fabricated piece.

(http://airboxer.com/images/rightsection016.jpg)

I put everywhere I could POR15.

(http://airboxer.com/images/rightsection017.jpg)

Now welding in the new piece I made.

(http://airboxer.com/images/rightsection018.jpg)

There it is welded and cleaned up.

(http://airboxer.com/images/rightsection019.jpg)

Now the inner rocker panel.

(http://airboxer.com/images/rightsection020.jpg)

Also replacing the section for the jack support.

(http://airboxer.com/images/rightsection021.jpg)

here the support section.

(http://airboxer.com/images/rightsection022.jpg)

(http://airboxer.com/images/rightsection023.jpg)

And here all cleaned up.

(http://airboxer.com/images/rightsection024.jpg)

I pained the comlete blank section with POR15, and next will be the rocker support and panel.

(http://airboxer.com/images/rightsection025.jpg)

I will continue this weekend.

Cheers
Engelbert


Title: Re: My Garage Build - The Airboxer Garage
Post by: rothaus on January 07, 2016, 05:03:35 PM
It's time for an update:

Prepped the rocker support for welding at the right side.

(http://airboxer.com/images/70_2015-12-05-1.jpg)

Here is it welded in.

(http://airboxer.com/images/70_2015-12-05-2.jpg)

Next mounting the fender and the door to make sure the outer rocker fits, and to fit the door post.

(http://airboxer.com/images/70_2015-12-05-3.jpg)

Looks like there is something missing.

(http://airboxer.com/images/70_2015-12-06-01.jpg)

I found some pictures to see what the piece looks like.

(http://airboxer.com/images/70_2015-12-06-02.jpg)

So I made that piece and welded it in.

(http://airboxer.com/images/70_2015-12-06-03.jpg)

Test fit for all the pieces.

(http://airboxer.com/images/70_2015-12-06-04.jpg)

Got the outer rocker welded in.

(http://airboxer.com/images/70_2015-12-12_1.jpg)

After the rocker is welded I fitted the piece of the quarter panel section.

(http://airboxer.com/images/70_2015-12-12_2.jpg)

And here is the piece complete welded it and cleaned up.

(http://airboxer.com/images/70_2015-12-14_1.jpg)

Now it's time to turn that car and move to the left side.

(http://airboxer.com/images/70_2015-12-20_1.jpg)

The outer rocker came after the few tack welds are ground off.

(http://airboxer.com/images/70_2015-12-20_2.jpg)

After I did the right side this didn't surprise me.

(http://airboxer.com/images/70_2015-12-20_3.jpg)

(http://airboxer.com/images/70_2015-12-20_4.jpg)

All these great designed pieces are history now.

(http://airboxer.com/images/70_2015-12-20_5.jpg)

(http://airboxer.com/images/70_2015-12-20_6.jpg)

After all the bad pieces are removed, it didn't look that bad on the inside.

(http://airboxer.com/images/70_2015-12-20_7.jpg)

More to come.

Cheers
Engelbert


Title: Re: My Garage Build - The Airboxer Garage
Post by: rothaus on January 25, 2016, 06:30:15 PM
Here is a little update:

Cut out some of the bad sections on the left side rocker section.

(http://airboxer.com/images/70-2015-12-21_1.jpg)

Making and fitting in a new piece.

(http://airboxer.com/images/70-2015-12-21_2.jpg)

Here is it welded in and cleaned up. I also had to cut out a small section of the fender mount section.

(http://airboxer.com/images/70-2015-12-21_3.jpg)

Next, I want to reuse the door post, since it was in good shape. Cleaning up and the crap from the backside.

(http://airboxer.com/images/70-2015-12-25_1.jpg)

As well the metal from the rear quarter panel.

(http://airboxer.com/images/70-2015-12-25_2.jpg)

Cleaned and blasted to be fitted back in.

(http://airboxer.com/images/70-2015-12-25_3.jpg)

I also cleaned up all the crap under the quarter panel.

(http://airboxer.com/images/70-2015-12-26_1.jpg)

Here is the mess that came off.

(http://airboxer.com/images/70-2015-12-27_1.jpg)

The old and new Rocker support. The old one looks like somebody beat the $hit out of it.

(http://airboxer.com/images/70-2015-12-27_2.jpg)

For the front I had to make a new piece, based on a picture I found on the net.

(http://airboxer.com/images/70-2015-12-27_3.jpg)

Now things coming back together, just for fitting for now.

(http://airboxer.com/images/70-2015-12-29_1.jpg)

Rocker is on as well the inner. All with sheet metal screws for now.

(http://airboxer.com/images/70-2015-12-29_2.jpg)

Fitting the new section of the quarter panel, and found that it's a bit short at the bottom, so I have to add a piece.

(http://airboxer.com/images/70-2015-12-30_1.jpg)

I also had some issues at the top. So I had to slot it and fit. The other side was better, anyway, still better then making it from scratch.

(http://airboxer.com/images/70-2015-12-30_2.jpg)

Once I got it all aligned, it was tiome to take it all back apart and start welding in the bottom piece of the door post I made.

(http://airboxer.com/images/70-2015-12-30_3.jpg)

Next is the inner rocker to weld in.

(http://airboxer.com/images/70-2015-12-31_1.jpg)

Then the Jack support.

(http://airboxer.com/images/70-2015-12-31_2.jpg)

The new rocker support is next.

(http://airboxer.com/images/70-2016-01-02_1.jpg)

Looks like I'm ready now for the outer rocker.

(http://airboxer.com/images/70-2016-01-02_2.jpg)

(http://airboxer.com/images/70-2016-01-02_3.jpg)

The outer rocker is welded in now.

(http://airboxer.com/images/70-2016-01-03_1.jpg)

Now I can go and extend the bottom piece of the quarter panel section.

(http://airboxer.com/images/70-2016-01-03_2.jpg)

As well the top section I had to slot and fit.

(http://airboxer.com/images/70-2016-01-03_3.jpg)

Getting there, the piece is almost done.

(http://airboxer.com/images/70-2016-01-09_1.jpg)

Done, next some more details to do.

(http://airboxer.com/images/70-2016-01-09_2.jpg)

Cheers
Engelbert


Title: Re: My Garage Build - The Airboxer Garage
Post by: jloehlein on January 25, 2016, 08:23:53 PM
That's a lot of sheet metal work!  Looks good.


Title: Re: My Garage Build - The Airboxer Garage
Post by: gunny on January 26, 2016, 03:58:32 PM
Yea,
You guys are good!
Can ya'll make me a carbon fiber frame for the Vette?

Gunny


Title: Re: My Garage Build - The Airboxer Garage
Post by: rothaus on January 31, 2016, 06:48:27 PM
I had a little interruption with the 70 911T work.

The Pepper S decided that he has a coolant leak. Since there was an issue with the coolant pipes made from plastic ????? I thought OK that's it, and I have to do it now. Disassemble the half engine just to find out they were done already at one point ????

It turned out, the problem was the expansion tank. WTF.

So now it starts, while you are in there..... OK, so found the starter in middle of the engine.

(http://www.airboxer.com/images/schtarter.jpg)

Great German engineering:::::

JaJa Franz, sehr gut, lez put tha shtarta in middle of ze engine, so nobodi can find it, und it will take ze porsche shop at least 12 hours to replace ze damn zing.

So, anyway, while I was in there, I replaced ze starter, since ze car had 100k miles.

Just got ze thing back zegether for the snow last Friday.

Cheers
Engelbert







Title: Re: My Garage Build - The Airboxer Garage
Post by: rothaus on March 09, 2016, 08:19:56 PM
OK, it's time for an update.

Some little patches on the fenders.

(http://airboxer.com/images/2016-02-06-01.jpg)

(http://airboxer.com/images/2016-02-07-01.jpg)

I didn't realized how bad the front bumper was.

(http://airboxer.com/images/2016-02-14-01.jpg)

So I ordered an new one.

(http://airboxer.com/images/2016-02-25-01.jpg)

So now the car was ready to go for an professional paint job. And here it is on the trailer on the way to Charles City.

(http://airboxer.com/images/2016-02-25-02.jpg)

Cheers
Engelbert


Title: Re: My Garage Build - The Airboxer Garage
Post by: jloehlein on March 10, 2016, 05:48:05 PM
Can't wait to see how the paint turns out!


Title: Re: My Garage Build - The Airboxer Garage
Post by: wahoo5 on March 12, 2016, 09:39:10 AM

Great German engineering:::::

JaJa Franz, sehr gut, lez put tha shtarta in middle of ze engine, so nobodi can find it, und it will take ze porsche shop at least 12 hours to replace ze damn zing.

So, anyway, while I was in there, I replaced ze starter, since ze car had 100k miles.


Too funny. Of course, it would be funnier if it weren't so true.

David


Title: Re: My Garage Build - The Airboxer Garage
Post by: whiteryder on March 12, 2016, 06:40:31 PM

I'm still ROTFL at hearing Engelbert doing a fake German accent.


Title: Re: My Garage Build - The Airboxer Garage
Post by: rothaus on June 27, 2016, 06:52:04 PM
My Powder Coating Oven worked great and I did a lot parts in there, however, the size is the limit.

So I decided to build a new oven for the larger parts.

I'm using metal studs like the those are used for office building walls.

This will be the bottom part.
(http://airboxer.com/garage/PC_Oven_001.jpg)

I used 18 gauge sheet metal for the bottom side and reinforced the corners with the same material for the coasters.
(http://airboxer.com/garage/PC_Oven_002.jpg)

I welded the nuts for the wheel mounting bolts at the inside, in case I have the remove the wheels.
(http://airboxer.com/garage/PC_Oven_003.jpg)

Test fitting the framing pieces.
(http://airboxer.com/garage/PC_Oven_004.jpg)

Insulation R13
(http://airboxer.com/garage/PC_Oven_005.jpg)

Bottom parts is complete
(http://airboxer.com/garage/PC_Oven_006.jpg)

Completing all the panels
(http://airboxer.com/garage/PC_Oven_007.jpg)

And Assembly of the box.
(http://airboxer.com/garage/PC_Oven_008.jpg)

Door is mounted, looks like a big fridge, LOL
(http://airboxer.com/garage/PC_Oven_009.jpg)

Next, the box for the controls
(http://airboxer.com/garage/PC_Oven_010.jpg)

(http://airboxer.com/garage/PC_Oven_011.jpg)

PID and solid state relay, this is the same stuff I used for the small oven, works great.
(http://airboxer.com/garage/PC_Oven_012.jpg)

This is why I have always some Ikea cutting board's in my material collection.
(http://airboxer.com/garage/PC_Oven_013.jpg)

Connection block for tha powa
(http://airboxer.com/garage/PC_Oven_014.jpg)

Here you go
(http://airboxer.com/garage/PC_Oven_015.jpg)

Got the thermocouple installed
(http://airboxer.com/garage/PC_Oven_016.jpg)

Wiring of the heating coils
(http://airboxer.com/garage/PC_Oven_017.jpg)

And the heating coils installed.
(http://airboxer.com/garage/PC_Oven_018.jpg)

The control box done and wired
(http://airboxer.com/garage/PC_Oven_019.jpg)

here a picture of the completed oven
(http://airboxer.com/garage/PC_Oven_020.jpg)

I used the inner part of an old oven where I also got the coils from, and cut out the section for the rack.
(http://airboxer.com/garage/PC_Oven_021.jpg)

A few more details, but I tested and all is working. Looking forward to powder coat the suspension part for the 1970 911.

Cheers
Engelbert


Title: Re: My Garage Build - The Airboxer Garage
Post by: jloehlein on June 28, 2016, 04:09:50 AM
nice!  how hot does the outer skin get when it's on?


Title: Re: My Garage Build - The Airboxer Garage
Post by: rothaus on June 29, 2016, 04:29:58 AM
I have not done any coating yet. I just had it up to 200 deg for a while to make sure all is working, and the outside stayed cold.

Cheers
Engelbert


Title: Re: My Garage Build - The Airboxer Garage
Post by: rothaus on July 01, 2016, 10:31:00 AM
My new to me Porsche 914

A few weeks ago I picked up a 914. It's a 76 2.0, Sunlight Yellow.

Here is the mandatory picture.

(http://airboxer.com/914/914-pic.jpg)

The car had already major surgery to fix the hell hole, so I cannot take credit for that, as well for the engine rebuild.

Here some pictures from the surgery
(http://airboxer.com/914/76-914-002.jpg)

(http://airboxer.com/914/76-914-003.jpg)

The car was converted to Carbs by the PO.
(http://airboxer.com/914/914-03.jpg)

So now it's to start work with some things these car have.

The Tach was not working and I found one for replacement. So, out with the old and in with the working one.

(http://airboxer.com/914/76-914-004.jpg)

This was a good opportunity to replace the BA7s instrument lights with LED vintage white.
(http://airboxer.com/914/76-914-005.jpg)

Here before
(http://airboxer.com/914/76-914-006.jpg)

And here after
(http://airboxer.com/914/76-914-007.jpg)

The next is the headlights, I cannot believe that people can still drive in the dark with those sealed beams.
(http://airboxer.com/914/76-914-008.jpg)

There you go.
(http://airboxer.com/914/76-914-009.jpg)

The backup light was not working, and I ended up to install a new wire from thr backup switch at the tranny to the housing. I didn't want to dig into the electr. panel at this time.

It it is not possible to hide that the car was painted with everything on it.  :bang:

(http://airboxer.com/914/76-914-010.jpg)

Also the cable had not chance to hide or escape from the painter.
(http://airboxer.com/914/76-914-011.jpg)

After opening the rear trunk a few times, it didn't looked right on the left hinge.

Here already removed for repair. The sleeve was broken out from the mounting point  :grrr:
(http://airboxer.com/914/76-914-012.jpg)

This is how it was installed.
(http://airboxer.com/914/76-914-013.jpg)

(http://airboxer.com/914/76-914-014.jpg)

(http://airboxer.com/914/76-914-015.jpg)

This is how it should be.
(http://airboxer.com/914/76-914-016.jpg)

OK, lets fix it. Drilling all the way true, and cut the thread.
(http://airboxer.com/914/76-914-017.jpg)

Weld on an additional nut from the backside.

(http://airboxer.com/914/76-914-018.jpg)

Ready to weld back in.
(http://airboxer.com/914/76-914-019.jpg)

Done
(http://airboxer.com/914/76-914-020.jpg)

Hinge back in, and ready to install the lid.
(http://airboxer.com/914/76-914-021.jpg)


So what else did I do ?

Exhaust
(http://airboxer.com/914/76-914-022.jpg)

Looks like that muffler doesn't do anything. So I took it out and found that the pre muffler is in good shape, just a lot of surface rust. So I cleaned it up and gave it a coat of hi heat black paint.
(http://airboxer.com/914/76-914-023.jpg)

Instead of the additional muffler, I just installed a pipe, and it still is not that loud. LOL.
(http://airboxer.com/914/76-914-024.jpg)

An other thing that needed some attention was the cover plate under the steering rack.
(http://airboxer.com/914/76-914-025.jpg)

(http://airboxer.com/914/76-914-026.jpg)

We will get to that later.....

I also found that the inner nut of the tie rod was not tied, which would not go anywhere since the outer one was tied.
(http://airboxer.com/914/76-914-027.jpg)

Here is the cover cleaned up.
(http://airboxer.com/914/76-914-028.jpg)

Now, there some issues that the windshield wiper would not stop, and if, it would stop anywhere, but not in parking position. So I started with the easy part, the switch.
(http://airboxer.com/914/76-914-029.jpg)

I removed it, and gave it a good cleaning with electronic cleaner and air, and gave it a try.
(http://airboxer.com/914/76-914-030.jpg)

Ha, now it was working, but the wiper stopped to park position in the middle of the windshield.

OK the motor seam to work and park, but in the wrong position. To get to the wimpywipermotor you have to remove the air blower housing. To remove the air blower housing you have to remove the gas tank.

OK, tank out
(http://airboxer.com/914/76-914-031.jpg)

It's always interesting what can be found
The fuel pump was a little to close to the brake fluid supply line for my, almost rubbing.
(http://airboxer.com/914/76-914-032.jpg)

So I removed it and modified the holder
Here before
(http://airboxer.com/914/76-914-033.jpg)

Here after
(http://airboxer.com/914/76-914-034.jpg)

Much more betta
(http://airboxer.com/914/76-914-035.jpg)

OK, back to the wimpywiper.
Blower out. There was really nothing left without yellow paint.
(http://airboxer.com/914/76-914-036.jpg)

OK, finally access the wiper motor
(http://airboxer.com/914/76-914-037.jpg)

There is also a nut from the dash board. The best is to remove the speedo to access it, unless you have 1 inch thin arms with 25 joints, LOL.
(http://airboxer.com/914/76-914-040.jpg)

I took the opportunity to clean out 40 years of collected dirt.
(http://airboxer.com/914/76-914-038.jpg)

After the adjustment of the linkage, so that the wiper stops at the bottom of the driver side, motor goes back in.
(http://airboxer.com/914/76-914-039.jpg)

Next to clean out the blower
(http://airboxer.com/914/76-914-041.jpg)

The motor looked good, the brushes were still good, and the motor bearings looked like sealed bearings and should be OK for another 40 year of dust.
(http://airboxer.com/914/76-914-042.jpg)

Ready to back in.
(http://airboxer.com/914/76-914-043.jpg)

I could get the yellow paint of the grill, but I had to paint it black. Back to Black.
(http://airboxer.com/914/76-914-044.jpg)


I will continue to fix all these little enoying things.

More to come.

Cheers
Engelbert


Title: Re: My Garage Build - The Airboxer Garage
Post by: rothaus on July 03, 2016, 05:41:29 PM
It's also time to get some pieces done for the 911.

I started to clean up some of the suspension parts, since I can now powder coat the larger items.

(http://airboxer.com/911T/911T_July-2016-001.jpg)

Here some of them done

(http://airboxer.com/911T/911T_July-2016-002.jpg)

Also did the pedal cluster.

Here the before

(http://airboxer.com/911T/911T_July-2016-003.jpg)

(http://airboxer.com/911T/911T_July-2016-004.jpg)

Here after the pan piece blasted and coated and with new bushings.

(http://airboxer.com/911T/911T_July-2016-005.jpg)

And ready for the time of installation.

(http://airboxer.com/911T/911T_July-2016-006.jpg)

Cheers
Engelbert


Title: Re: My Garage Build - The Airboxer Garage
Post by: rothaus on July 05, 2016, 05:25:47 PM
A little update:

Here is the steering rack panel back in. It's funny this was the thing what looked worse, now the rest looks crappy.

(http://airboxer.com/914/914-june-16_003.jpg)

So now that the wiper works correct, I can go back the LED's for the external marker.

I was wondering why the turning signal does that hyper blinking. When I pulled out the fuse box to replace the flasher relay.... Tadaaa. The original relay must have gone bad, and somebody installed a replacement relay. LOL.

That thing hanging on the 3 wires with electrical tape.

(http://airboxer.com/914/914-june-16_001.jpg)

Since this section was in need of some cleaning, I also pulled the Light, Hazard, and Fog light switch, to give them a good scrub, with oileater and electronic cleaner.

(http://airboxer.com/914/914-june-16_002.jpg)

Here is the new flasher relay installed , it's # 3 from right. They all look so happy now nice and clean.

(http://airboxer.com/914/914-june-16_004.jpg)

The new flasher work correct with the LED's, so all can go back in.

Next I checked all the brakes, since I want to go to get the car inspected. The rear looked all good, but the front brakes needed some overhauln. That one pad had less than a mm left.

New pads and the caliper rebuild.
(http://airboxer.com/914/914-june-16_005.jpg)

Here are they ready to get back on.
(http://airboxer.com/914/914-june-16_006.jpg)

Next is the front spoiler, there were some cracks and on the right side it was broken out where it mounts to the fender.

(http://airboxer.com/914/914-june-16_007.jpg)

I took it off and re-enforced it from the inside. That spoiler is paper thin.

(http://airboxer.com/914/914-june-16_008.jpg)

After that I gave it a quick Rustolium satin black paint job, and put it back on. Not sure what I going to do with that later, because I plan to backdate to metal bumpers, not sure yet.

(http://airboxer.com/914/914-june-16_009.jpg)

To be continued

Cheers
Engelbert


Title: Re: My Garage Build - The Airboxer Garage
Post by: rothaus on August 18, 2016, 05:39:02 AM
A little update on the 1970 911T:

The car should be finish painted this week.

In the meantime I getting some parts ready.

Powder coated some engine tin pieces together with the torsion bar covers.

(http://airboxer.com/911T/PC-Parts.jpg)

The Banana arms are ready, bushings and bearings are in.

(http://airboxer.com/911T/banana-arms.jpg)

The Steering rack is assembled, I decided to go with the Turbo tie rods.

(http://airboxer.com/911T/70-911t-steering.jpg)

Started with the struts and hubs. Found some better hubs and the rotors were in great condition, just had to blast them. The hubs were blasted and got a clear coat.

(http://airboxer.com/911T/front-struts-911T-01.jpg)

(http://airboxer.com/911T/front-struts-911T-03.jpg)

(http://airboxer.com/911T/front-struts-911T-04.jpg)

Cheers
Engelbert



Title: Re: My Garage Build - The Airboxer Garage
Post by: rothaus on September 25, 2016, 06:36:00 AM
The car is back from painting.

I rented an enclosed trailer, so will not have already paint chipped off on the way home.
(http://airboxer.com/911T/911T-08-29-01.jpg)

Inside the garage and ready to on the lift.

(http://airboxer.com/911T/911T-08-29-04.jpg)


I just finished some details for the trunk and under the car.

Here some pictures.

(http://airboxer.com/911T/70-911T-detail-01.jpg)

(http://airboxer.com/911T/70-911T-detail-02.jpg)

(http://airboxer.com/911T/70-911T-detail-03.jpg)

(http://airboxer.com/911T/70-911T-detail-04.jpg)

(http://airboxer.com/911T/70-911T-detail-05.jpg)

(http://airboxer.com/911T/70-911T-detail-06.jpg)

(http://airboxer.com/911T/70-911T-detail-07.jpg)


Also restored the engine shraud, so it's ready when ever I need it.

(http://airboxer.com/911T/70-911T-shraud.jpg)

Still waiting for some bits and pieces for the suspension, so I can mount it and get it on the wheels.

Cheers
Engelbert


Title: Re: My Garage Build - The Airboxer Garage
Post by: jloehlein on September 25, 2016, 11:46:02 AM
Looking good!  Figured you might appreciate this Porsche 4 cylinder on an engine stand that I saw on vacation.

(https://c6.staticflickr.com/9/8184/29526923701_53bd6ee256_z.jpg)


Title: Re: My Garage Build - The Airboxer Garage
Post by: rothaus on October 12, 2016, 06:08:51 PM
This is an amazing engine... Wow.

Here is an update on the 911T

I started actually the assembly of the suspension of the 911T.

Here are some pictures.

Banana Arms

(http://airboxer.com/911T/911T-2016-10-11-01.jpg)

(http://airboxer.com/911T/911T-2016-10-11-02.jpg)

(http://airboxer.com/911T/911T-2016-10-11-03.jpg)

Here are some of the rear brake components restored.

(http://airboxer.com/911T/911T-2016-10-12-01.jpg)

Here more rear installation.

(http://airboxer.com/911T/911T-2016-10-12-02.jpg)

(http://airboxer.com/911T/911T-2016-10-12-03.jpg)

Cheers
Engelbert


Title: Re: My Garage Build - The Airboxer Garage
Post by: rothaus on October 14, 2016, 05:58:26 PM
Here are a few more pictures how things come together.

(http://airboxer.com/911T/70-911T-2016-10-14-01.jpg)

Starting the front suspension

(http://airboxer.com/911T/70-911T-2016-10-14-02.jpg)

Steering linkage is in as well.

(http://airboxer.com/911T/70-911T-2016-10-14-03.jpg)

Struts are in.

(http://airboxer.com/911T/70-911T-2016-10-14-04.jpg)

T-Bars installed.

(http://airboxer.com/911T/70-911T-2016-10-14-05.jpg)

(http://airboxer.com/911T/70-911T-2016-10-14-06.jpg)

Struts are in.

(http://airboxer.com/911T/70-911T-2016-10-14-07.jpg)

A little bit of rear drum brake hardware porn. All restored.

(http://airboxer.com/911T/70-911T-2016-10-14-08.jpg)

And finally it is on the wheels. I just use some of the space saver wheels. I inflated them 3 weeks ago and they holding up very nice.

(http://airboxer.com/911T/70-911T-2016-10-14-09.jpg)

I started to sort out and install the Frunk wire harnes

(http://airboxer.com/911T/70-911T-2016-10-14-10.jpg)

Fuse box installed, still some wires to sort out

(http://airboxer.com/911T/70-911T-2016-10-14-11.jpg)

More to sort out for the Dash section.

(http://airboxer.com/911T/70-911T-2016-10-14-12.jpg)

Cheers
Engelbert


Title: Re: My Garage Build - The Airboxer Garage
Post by: wahoo5 on October 20, 2016, 07:13:48 PM
Very impressive, Englebert. It will really cool to see the final result.

David


Title: Re: My Garage Build - The Airboxer Garage
Post by: rothaus on October 23, 2016, 09:25:33 AM
Thanks David

Continuing on the trunk wiring.

Nice to have today's technology.

(http://www.airboxer.com/911T/70-911T_cable-01.jpg)

Most is sorted out, the instruments will come in later.

(http://www.airboxer.com/911T/70-911T_cable-02.jpg)

I started to prepare the ventilation system

(http://www.airboxer.com/911T/70-911T_venti-01.jpg)

Need to be disassembled, cleaned and see if anything need repaired or replaced.

(http://www.airboxer.com/911T/70-911T_venti-02.jpg)

Since this was never disassembled the dust is all there.

(http://www.airboxer.com/911T/70-911T_venti-03.jpg)

Unfortunately the fan is broken, and need to be replaced. I couldn't find the fan only. I found the motor separate, or just the complete motor and fan. I should have a new one next week.

(http://www.airboxer.com/911T/70-911T_venti-04.jpg)

The support pieces from the housing where it bolts on the body, need some TLC. So I removed them and they get blasted and re-plated.

(http://www.airboxer.com/911T/70-911T_venti-05.jpg)

All the plastic pieces and metal are in great shape and look like new after cleaning.

(http://www.airboxer.com/911T/70-911T_venti-06.jpg)

(http://www.airboxer.com/911T/70-911T_venti-07.jpg)

However, the plaps and linkage I will restore, and put a new seal on it.

(http://www.airboxer.com/911T/70-911T_venti-08.jpg)

(http://www.airboxer.com/911T/70-911T_venti-09.jpg)

The brake line set came in, so I installed the long line in the center tunnel.

(http://www.airboxer.com/911T/70-911T_brakeline-01.jpg)

(http://www.airboxer.com/911T/70-911T_brakeline-02.jpg)

(http://www.airboxer.com/911T/70-911T_brakeline-03.jpg)

Since the brake line is installed now I can also do the shifter. Got the shif rod back in and all new bushings for the shifter.

(http://www.airboxer.com/911T/70-911T_shifter-01.jpg)

Cheers
Engelbert


Title: Re: My Garage Build - The Airboxer Garage
Post by: rothaus on November 02, 2016, 04:01:57 PM
OK, a little update on the progress I made.

Cleaned and plated the fan flaps and linkage.

(http://airboxer.com/911T/2016-10-venty-01.jpg)

Made new seals from 4mm foam sheet

(http://airboxer.com/911T/2016-10-venty-02.jpg)

Test fit it.

(http://airboxer.com/911T/2016-10-venty-03.jpg)

Also plated the little clips which hole the fan housing together.

(http://airboxer.com/911T/2016-10-venty-04.jpg)

The fan housing is complete now with new motor and fan.

(http://airboxer.com/911T/2016-10-venty-05.jpg)

(http://airboxer.com/911T/2016-10-venty-06.jpg)

Here it is, ready for the car.

(http://airboxer.com/911T/2016-10-venty-07.jpg)

Since I'm still waiting for a few things to happen before I continue with the installation off any further parts, I started to tear down the engine.

(http://airboxer.com/911T/2016-10-engine-01.jpg)

Timing chain housings are off.

(http://airboxer.com/911T/2016-10-engine-02.jpg)

Heads and cam housing ready to come off. All head studs where in tact.

(http://airboxer.com/911T/2016-10-engine-03.jpg)

Cylinders are ready to come off.

(http://airboxer.com/911T/2016-10-engine-04.jpg)

Here the parts, damn, a lot to clean.

(http://airboxer.com/911T/2016-10-engine-05.jpg)

The cylinders and pistons are removed and the head studs are next.

(http://airboxer.com/911T/2016-10-engine-06.jpg)

The studs came out without fight, I only used 2 nuts.

(http://airboxer.com/911T/2016-10-engine-07.jpg)

The casing is open.

(http://airboxer.com/911T/2016-10-engine-08.jpg)

And the crank shaft is out.

(http://airboxer.com/911T/2016-10-engine-09.jpg)

Here it is.

(http://airboxer.com/911T/2016-10-engine-10.jpg)

I found that the last 2 rod bearing have some wear, Cyl # 3 and 6.

(http://airboxer.com/911T/2016-10-engine-11.jpg)

(http://airboxer.com/911T/2016-10-engine-12.jpg)

I also took the heads of the cam housing and removed the valves.

(http://airboxer.com/911T/2016-10-engine-13.jpg)

Will continue soon, now I have to clean all these parts, so I can inspect them.

Cheers
Engelbert


Title: Re: My Garage Build - The Airboxer Garage
Post by: rothaus on November 23, 2016, 12:46:42 PM
Some about the 914.

I didn't like the rubber bumpers, I want to backdate the bumpers to metal.

So, I found a front and rear metal bumper and the top pieces in good condition. The bumper self were painted and need some work.

Here is the front one where I have closed the hole from the bumperettes. It also needed a little banging to get it straight at those areas.

(http://airboxer.com/914/front-bumper-01.jpg)

(http://airboxer.com/914/front-bumper-02.jpg)

The rear bumper showed some rust once I removed the bumperettes (or Stosstangenhoerner in German).

Here is it after stripping the paint off, and I used some acid to get rid of some rust on the inside. It looks worse than it is, it's only some flash rust from the acid.

(http://airboxer.com/914/rear-bumper-01.jpg)

Here is the area that need repair
(http://airboxer.com/914/rear-bumper-02.jpg)

Cut out the bad section
(http://airboxer.com/914/rear-bumper-03.jpg)

Fit the new piece
(http://airboxer.com/914/rear-bumper-04.jpg)

Weld it in
(http://airboxer.com/914/rear-bumper-05.jpg)

Clean up and done

(http://airboxer.com/914/rear-bumper-06.jpg)

Got it primed and ready for final sanding and painting.

(http://airboxer.com/914/914-Bumper_Paint_01.jpg)

Here they are now painted.

(http://airboxer.com/914/914-Bumper_Paint_02.jpg)

I got to the point to see if the yellow bumper will fit and started to remove the rubber bumpers and support. I know when I bought the car that something happen at that rear corner.

(http://airboxer.com/914/914-B-Backdate-001.jpg)

I did not expect that it will become such a project.

(http://airboxer.com/914/914-B-Backdate-002.jpg)

After seeing this, I started to dig in and get the body filler off.

(http://airboxer.com/914/914-B-Backdate-003.jpg)

Oh boy, somebody did some hi-tech repair.

(http://airboxer.com/914/914-B-Backdate-004.jpg)

Looks like I found a panel piece, so I can cut out the section and put in a new piece.

I want the piece first before I do any cutting. So I move to the front. At that corner it was also obvious that some repair was done at one time.

(http://airboxer.com/914/914-B-Backdate-005.jpg)

It was not as bad as at the rear end.

(http://airboxer.com/914/914-B-Backdate-006.jpg)

There were 3 holes when somebody tried to pull it out, so I welded the holes and massaged the rest.

(http://airboxer.com/914/914-B-Backdate-007.jpg)

While I was on it, I welded the side marker hole. I never liked the look of them.

(http://airboxer.com/914/914-B-Backdate-008.jpg)

I was pocking around in the rear trunk and found 2 areas which looked suspicious.

(http://airboxer.com/914/914-B-Backdate-009.jpg)

There were some small rust areas which were masterful repaired with body filler.

(http://airboxer.com/914/914-B-Backdate-010.jpg)

After removing the material it showed 2 sections which need some attention.

(http://airboxer.com/914/914-B-Backdate-011.jpg)

I removed the exhaust heat shield below.

(http://airboxer.com/914/914-B-Backdate-012.jpg)

And found that one of the support was hanging on body filler. That goop of chip guard must have been there since it came out of the factory.

(http://airboxer.com/914/914-B-Backdate-013.jpg)

A view from the bottom side.

(http://airboxer.com/914/914-B-Backdate-014.jpg)

Here I have the sections cut out.

(http://airboxer.com/914/914-B-Backdate-015.jpg)

I made new pieces to be welded back in.

(http://airboxer.com/914/914-B-Backdate-016.jpg)

Here they are welded back in. Pardon the ugly welds, I will clean them up.

(http://airboxer.com/914/914-B-Backdate-017.jpg)

Here is it cleaned up.

(http://airboxer.com/914/914-B-Backdate-018.jpg)

Another view from the bottom side, with the heat shield support welded back on.

(http://airboxer.com/914/914-B-Backdate-019.jpg)

Cheers
Engelbert


Title: Re: My Garage Build - The Airboxer Garage
Post by: rothaus on December 02, 2016, 04:18:51 PM
Here is an update.

I keep finding more work as I go. I should not have started that Bumper conversion project, and now I'm on a point of no return. Anyway, this will not be a complete restoration at this time.

I found a good replacement piece for the rear right corner.

(http://airboxer.com/914/B_Backdate_101.jpg)

Careful removed the spot welds

(http://airboxer.com/914/B_Backdate_102.jpg)

I found a small area which needed a little patch.

(http://airboxer.com/914/B_Backdate_103.jpg)

While I was fitting the new piece, I also made the patch.

(http://airboxer.com/914/B_Backdate_104.jpg)

One more small section to be fixed at the bottom, but no big deal.

(http://airboxer.com/914/B_Backdate_105.jpg)

Here it is, ready to get welded in.

(http://airboxer.com/914/B_Backdate_106.jpg)

I prepped the section of the car with some primer, chip guard, and paint, on the section, I cannot get easy later on.

(http://airboxer.com/914/B_Backdate_107.jpg)

Here is the new panel complete welded in.

(http://airboxer.com/914/B_Backdate_108.jpg)

Here is what it looked before.

(http://airboxer.com/914/914-B-Backdate-004.jpg)

With that I moved to the front bumper section. When I removed the trunk seal, I found some additional section, which need some repair.

(http://airboxer.com/914/B_Backdate_109.jpg)

(http://airboxer.com/914/B_Backdate_110.jpg)

OK, cutting out.

(http://airboxer.com/914/B_Backdate_111.jpg)

Welding in.

(http://airboxer.com/914/B_Backdate_112.jpg)

More pieces, this was above of the headlight cover, hidden under the trunk seal.

(http://airboxer.com/914/B_Backdate_113.jpg)

I painted that section for now, so I can concentrate later for the external section.

(http://airboxer.com/914/B_Backdate_114.jpg)

Cheers
Engelbert


Title: Re: My Garage Build - The Airboxer Garage
Post by: rothaus on December 21, 2016, 07:35:29 AM
Here is a little update. I need to get this car off the lift. I was able to touch up the corners with yellow. It's not a super nice paint job, but it will do for now.

Always looks better on the pictures and in the sun, LOL.

(http://airboxer.com/914/2016-12-13-914-01.jpg)

(http://airboxer.com/914/2016-12-13-914-02.jpg)

Ready for assembly. Now I looks at these parts and need to do something. I cannot install it as is.

(http://airboxer.com/914/2016-12-13-914-03.jpg)

I got the Headlight supports Powder coated. The most work was to get them all clean blasted.
(http://airboxer.com/914/914-12-16-01.jpg)

Installed
(http://airboxer.com/914/914-12-16-02.jpg)

(http://airboxer.com/914/914-12-16-03.jpg)

Front Bumper is mounted.
(http://airboxer.com/914/914-12-16-04.jpg)

I just need to come up with a solution for the fog lights. I want to use the fog lights which were on the car with the rubber bumpers. But I will have some time to think until it's drive time again.

(http://airboxer.com/914/914-12-16-05.jpg)

Getting the rear side ready.
(http://airboxer.com/914/914-12-16-06.jpg)

Bumper is installed.
(http://airboxer.com/914/914-12-16-07.jpg)

Just need to find a nice plate holder and a plug for the hole.
(http://airboxer.com/914/914-12-16-08.jpg)

That's it for now. Need to do some wiring in the parking garage and add insulation to the ceiling, etc. then get back on the 1970 911.

Happy Holidays to all
Engelbert



Title: Re: My Garage Build - The Airboxer Garage
Post by: MikeDe on December 30, 2016, 06:20:27 AM
I always enjoy seeing your work.  It's both inspiring and depressing at the same time.  Inspiring because it can be done and depressing because I know I couldn't do it.  Looks great!!


Title: Re: My Garage Build - The Airboxer Garage
Post by: rothaus on January 06, 2017, 08:07:21 AM
Getting back on the 911.

Started sorting out some items and blasted the Cylinder cooling sheets.

(http://www.airboxer.com/911T/70-911T-Cyl-tin-01.jpg)

And powder coated them. One is missing in the picture. That need some small area repaired.

(http://www.airboxer.com/911T/70-911T-Cyl-tin-02.jpg)

Small stuff, but there will be more progress coming up soon.

Happy New Year
Engelbert


Title: Re: My Garage Build - The Airboxer Garage
Post by: rothaus on February 20, 2017, 07:04:09 AM
Here is a little update:

I started to clean more engine parts. No comment needed.

(http://airboxer.com/911T/2017-911T-001.jpg)

(http://airboxer.com/911T/2017-911T-002.jpg)

(http://airboxer.com/911T/2017-911T-003.jpg)

(http://airboxer.com/911T/2017-911T-004.jpg)

(http://airboxer.com/911T/2017-911T-005.jpg)

(http://airboxer.com/911T/2017-911T-006.jpg)

(http://airboxer.com/911T/2017-911T-007.jpg)

The parts not seen in this picture will be stripped and plated
(http://airboxer.com/911T/2017-911T-008.jpg)

(http://airboxer.com/911T/2017-911T-009.jpg)

(http://airboxer.com/911T/2017-911T-010.jpg)

(http://airboxer.com/911T/2017-911T-011.jpg)

(http://airboxer.com/911T/2017-911T-012.jpg)

I started to take a look at the seats.
(http://airboxer.com/911T/2017-911T-013.jpg)

The hinges looked pretty rough.
(http://airboxer.com/911T/2017-911T-014.jpg)

But I was able to clean them up.
(http://airboxer.com/911T/2017-911T-015.jpg)

Taking the seat bottom apart.
(http://airboxer.com/911T/2017-911T-016.jpg)

(http://airboxer.com/911T/2017-911T-017.jpg)

I think I will need to find replacement for the old horse hair stuff and replace it with some foam.

(http://airboxer.com/911T/2017-911T-018.jpg)

I also want to find a way to make the seat bottom a bit more firm.

That's it for today.
Cheers
Engelbert


Title: Re: My Garage Build - The Airboxer Garage
Post by: rothaus on February 23, 2017, 03:43:40 PM
Continue on the disassembly of the seats.

(http://airboxer.com/911T/2017-911T-021.jpg)

These seat shells are not painted from the factory. I think they never expected these cars last that long.

(http://airboxer.com/911T/2017-911T-022.jpg)

I cleaned them up a bit.

(http://airboxer.com/911T/2017-911T-023.jpg)

And gave them some paint.

(http://airboxer.com/911T/2017-911T-024.jpg)

I got a set of new covers on the way, as well the bottom foam.

Next the seat belts.

(http://airboxer.com/911T/2017-911T-025.jpg)

I hate when people put masking take on parts like this and then the tape stays on it for over 10 years or longer.

(http://airboxer.com/911T/2017-911T-026.jpg)

They cleaned up OK, and are ready for assembly.

(http://airboxer.com/911T/2017-911T-027.jpg)

(http://airboxer.com/911T/2017-911T-028.jpg)

The rear seat came out nice as well after some scrubbing.

(http://airboxer.com/911T/2017-911T-029.jpg)

I picked up some vinyl today, to recover the rear shelf and the rear side panels, knee pads, etc.

Cheers
Engelbert