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Author Topic: My Garage Build - The Airboxer Garage  (Read 112331 times)
rothaus
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« Reply #150 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.



I used some heavy canvas instead the original black paper to connect the vertical and horizontal section.



Staple it all on.



Next Recover the 2 small pieces left and right behind the B-Pillar.





Continue with the new carpet.



And some new vinyl pieces left and right





More new carpet



Now the floor boards need some attention.



Why always replace if it can be repaired. Now I know why I have a scrollsaw.



All glued together and ready to install



Now it's time to attack the seats



Removing all the power stuff





Separating the back. There is a square pin that need to be pulled out, after the little socket head screw is removed.





Removing the old cover, or what is left.. LOL.



Some hidden hog rings need to be removed. Always take plenty pictures.



And off comes the skin.



Next the bottom section.





The foam of these seats were in good shape and I didn't need to replace any pieces.



Replacing the overlay of the side sections.



And putting it back together.



And here they are all new leather. The still have some wrinkles, but with a bit steam it will be fine.



More to come.

Cheers
Engelbert
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Engelbert's Garage | My Porsche Video | The AIRBOXER Garage Build
2006 Cayenne S Work Horse
2006 Boxster the Puppy
1988 944 Turbo
1986 944 the beater
1982 911 SC
1978 VW Super Beetle Cabrio LTP
1976 914 in the works
1971 911T AX Car
1970 911T Current Project
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« Reply #151 on: September 09, 2014, 03:19:20 PM »

You are a magician.
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If you can leave two black stripes from the exit of one corner to the braking zone of the next, you have enough horsepower. Mark Donohue
rothaus
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« Reply #152 on: September 11, 2014, 05:43:14 PM »

More progress.

Now it's time to work on the door panels.



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.



On the workbench for surgery.



I found that the bolt where the cable go thru was lose.



With the cables in the way the bold cannot be screwed in and tightening.



So I had to remove all the pins from the socket, to get the cable out.



Now the bolt can go back in.



Next the cable and put it all back together.



Tested the mirror and switch and it's all working. Smiley

More for the coming weekend.

Cheers
Engelbert
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Engelbert's Garage | My Porsche Video | The AIRBOXER Garage Build
2006 Cayenne S Work Horse
2006 Boxster the Puppy
1988 944 Turbo
1986 944 the beater
1982 911 SC
1978 VW Super Beetle Cabrio LTP
1976 914 in the works
1971 911T AX Car
1970 911T Current Project
rothaus
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« Reply #153 on: September 18, 2014, 06:01:06 PM »

A little update:

Installed the new headliner.



I got the 993 top made vor the 911 and 964



This looks much better and it actually fits.



I had to replace the tension cables on both sides, there is a left and right side.



The old once were all messed up.



Here installed.



Looks almost real



Some pieces to be recovered with new vinyl.



The carpet is also installed now, and it looks almost like a car again.



Sorting the cables for the new stereo.



The seats are in and I can actually sit in the car. Cheesy



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
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Engelbert's Garage | My Porsche Video | The AIRBOXER Garage Build
2006 Cayenne S Work Horse
2006 Boxster the Puppy
1988 944 Turbo
1986 944 the beater
1982 911 SC
1978 VW Super Beetle Cabrio LTP
1976 914 in the works
1971 911T AX Car
1970 911T Current Project
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« Reply #154 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!
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rothaus
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« Reply #155 on: September 19, 2014, 05:10:05 PM »

No animal in this car. The rear seats are still missing, haha.

Cheers
Engelbert
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Engelbert's Garage | My Porsche Video | The AIRBOXER Garage Build
2006 Cayenne S Work Horse
2006 Boxster the Puppy
1988 944 Turbo
1986 944 the beater
1982 911 SC
1978 VW Super Beetle Cabrio LTP
1976 914 in the works
1971 911T AX Car
1970 911T Current Project
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« Reply #156 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
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David Ogburn
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rothaus
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« Reply #157 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
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Engelbert's Garage | My Porsche Video | The AIRBOXER Garage Build
2006 Cayenne S Work Horse
2006 Boxster the Puppy
1988 944 Turbo
1986 944 the beater
1982 911 SC
1978 VW Super Beetle Cabrio LTP
1976 914 in the works
1971 911T AX Car
1970 911T Current Project
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« Reply #158 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.



I removed the Tank and Oil level gauge and took a look what can be done.



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.



I went and started to clean up the rings with the dremmel sander, and they came out OK.



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.



What a difference.



Next the Oil temp and Druck



The tach and the speedo I just cleaned as good as possible and put it back in with the new LED's installed.



Last but not least the clock.



Here a picture with all back in.



The next thing to fix, was a broken log from the steering column cover.



After cleaning and some superglue, it's ready to go back on.



The next thing before the steering wheel goes on.



Install one of these nice bearings from Mitch Lealand



More next weekend.

Cheers
Engelbert


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Engelbert's Garage | My Porsche Video | The AIRBOXER Garage Build
2006 Cayenne S Work Horse
2006 Boxster the Puppy
1988 944 Turbo
1986 944 the beater
1982 911 SC
1978 VW Super Beetle Cabrio LTP
1976 914 in the works
1971 911T AX Car
1970 911T Current Project
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« Reply #159 on: October 23, 2014, 12:37:20 PM »

Have you entered yet?

http://classicmotorsports.net/events/show-us-your-shop/
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James

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rothaus
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« Reply #160 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
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Engelbert's Garage | My Porsche Video | The AIRBOXER Garage Build
2006 Cayenne S Work Horse
2006 Boxster the Puppy
1988 944 Turbo
1986 944 the beater
1982 911 SC
1978 VW Super Beetle Cabrio LTP
1976 914 in the works
1971 911T AX Car
1970 911T Current Project
rothaus
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« Reply #161 on: October 23, 2014, 05:31:12 PM »

Drove the Cab around last weekend.

Stopped for some pictures.







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
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Engelbert's Garage | My Porsche Video | The AIRBOXER Garage Build
2006 Cayenne S Work Horse
2006 Boxster the Puppy
1988 944 Turbo
1986 944 the beater
1982 911 SC
1978 VW Super Beetle Cabrio LTP
1976 914 in the works
1971 911T AX Car
1970 911T Current Project
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« Reply #162 on: October 23, 2014, 05:34:01 PM »

It is looking good.

David
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David Ogburn
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rothaus
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« Reply #163 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
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Engelbert's Garage | My Porsche Video | The AIRBOXER Garage Build
2006 Cayenne S Work Horse
2006 Boxster the Puppy
1988 944 Turbo
1986 944 the beater
1982 911 SC
1978 VW Super Beetle Cabrio LTP
1976 914 in the works
1971 911T AX Car
1970 911T Current Project
rothaus
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« Reply #164 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.



I's back running.

So I made a little progress on the door panels. The old once where actually worse than I expected.



Here is one more picture when I had the vinyl off.



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.





Here is the new finish stitched vinyl.



Looks like its a good match to the leather seat.



More next weekend, tomorrow is the last autocross for this year.

Cheers
Engelbert
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Engelbert's Garage | My Porsche Video | The AIRBOXER Garage Build
2006 Cayenne S Work Horse
2006 Boxster the Puppy
1988 944 Turbo
1986 944 the beater
1982 911 SC
1978 VW Super Beetle Cabrio LTP
1976 914 in the works
1971 911T AX Car
1970 911T Current Project
rothaus
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« Reply #165 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.



Here with the new vinyl.







This time the panels are installed with vapor barrier



Here old and new comparison.



And finish installed.



One more picture of the car.



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
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Engelbert's Garage | My Porsche Video | The AIRBOXER Garage Build
2006 Cayenne S Work Horse
2006 Boxster the Puppy
1988 944 Turbo
1986 944 the beater
1982 911 SC
1978 VW Super Beetle Cabrio LTP
1976 914 in the works
1971 911T AX Car
1970 911T Current Project
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« Reply #166 on: November 13, 2014, 09:14:03 PM »

Very nice work. It is really looking good.
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David Ogburn
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« Reply #167 on: November 14, 2014, 05:54:55 AM »


Beautiful!!

Is that round thing above the arm rest the door handle?
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rothaus
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« Reply #168 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

Cheers
Engelbert
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Engelbert's Garage | My Porsche Video | The AIRBOXER Garage Build
2006 Cayenne S Work Horse
2006 Boxster the Puppy
1988 944 Turbo
1986 944 the beater
1982 911 SC
1978 VW Super Beetle Cabrio LTP
1976 914 in the works
1971 911T AX Car
1970 911T Current Project
rothaus
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« Reply #169 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
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Engelbert's Garage | My Porsche Video | The AIRBOXER Garage Build
2006 Cayenne S Work Horse
2006 Boxster the Puppy
1988 944 Turbo
1986 944 the beater
1982 911 SC
1978 VW Super Beetle Cabrio LTP
1976 914 in the works
1971 911T AX Car
1970 911T Current Project
rothaus
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« Reply #170 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.



Clean it all up, and ready for some new sheet metal.





And one more section done.



More to cut out inside the engine compartment





My plan is to get the welding done by New Year, cross your fingers.Smiley

More to come.

Cheers
Engelbert
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Engelbert's Garage | My Porsche Video | The AIRBOXER Garage Build
2006 Cayenne S Work Horse
2006 Boxster the Puppy
1988 944 Turbo
1986 944 the beater
1982 911 SC
1978 VW Super Beetle Cabrio LTP
1976 914 in the works
1971 911T AX Car
1970 911T Current Project
rothaus
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« Reply #171 on: January 07, 2015, 06:12:42 PM »

I made some progress over the holidays.

Finished the rear inside corners.



So now it's time to move to the right rear corner behind the rear wheel section.



As more I poke around as more I find.



keep cutting until I hit good material.



Welding in more pieces.



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.



The bottom section I had to make new.



With the rear section done, it's time to move to the left front section, where I had to cut out quit some rust.



Making more pieces and welding in.



One down, a lot more to go.



It's coming slowly together



Now the outside.



And finally the outer skin.



The black piece was purchased.



Almost done



And finally with the rip piece welded in.



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.





Here a picture of the bad sections cut out.



Here are the pieces which need to be replaced.



The bottom section welded in.



Re-creating the replacement pieces with holes, etc.



And ready to be welded in.



Done with this on.



Now all the bad stuff is cut out. This is not an easy section, all is 3 dimensional.



Here a new piece.



And the last little piece ready to weld.



Here it is, all welded and cleaned up.



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
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Engelbert's Garage | My Porsche Video | The AIRBOXER Garage Build
2006 Cayenne S Work Horse
2006 Boxster the Puppy
1988 944 Turbo
1986 944 the beater
1982 911 SC
1978 VW Super Beetle Cabrio LTP
1976 914 in the works
1971 911T AX Car
1970 911T Current Project
rothaus
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« Reply #172 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.





A few more things to do, but this turned out to be a great little car.

Cheers
Engelbert
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Engelbert's Garage | My Porsche Video | The AIRBOXER Garage Build
2006 Cayenne S Work Horse
2006 Boxster the Puppy
1988 944 Turbo
1986 944 the beater
1982 911 SC
1978 VW Super Beetle Cabrio LTP
1976 914 in the works
1971 911T AX Car
1970 911T Current Project
rothaus
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« Reply #173 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.





OK, here is the next step to complete the plug.

First I taped the Styrofoam before adding Bondo.





Now it get's messy, all this ugly bondo, juck..



More bondo and sanding and more bondo and more sanding, you get the idea, until it looks like I want to.





Now it get ugly again for the molds.



After the molds are done the plugs can come off, and gute nacht to the dump.



OK, so now I have molds.



Now I make the flares.



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.





Here is a picture of the front flare test fit.



The Front bumper/spoiler need some modification as well.







Here is a picture of the car during the alignment, still with the 16" wheels at the rear end.



Here is the finished product with the 17" wheels at the rear end.



No problem with rubbing like last year.

Cheers
Engelbert
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Engelbert's Garage | My Porsche Video | The AIRBOXER Garage Build
2006 Cayenne S Work Horse
2006 Boxster the Puppy
1988 944 Turbo
1986 944 the beater
1982 911 SC
1978 VW Super Beetle Cabrio LTP
1976 914 in the works
1971 911T AX Car
1970 911T Current Project
rothaus
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« Reply #174 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.











Cheers
Engelbert
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Engelbert's Garage | My Porsche Video | The AIRBOXER Garage Build
2006 Cayenne S Work Horse
2006 Boxster the Puppy
1988 944 Turbo
1986 944 the beater
1982 911 SC
1978 VW Super Beetle Cabrio LTP
1976 914 in the works
1971 911T AX Car
1970 911T Current Project
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