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Author Topic: My Garage Build - The Airboxer Garage  (Read 112144 times)
rothaus
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« Reply #125 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

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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 #126 on: January 22, 2014, 05:33:20 PM »

Ha, just started a new page

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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 #127 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
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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 #128 on: January 30, 2014, 05:57:53 PM »

Little update:

Finishing up that bottom corner



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





The last outside piece welded and cleaned up.





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





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





 This was the last piece of the rear right section. 



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 #129 on: February 02, 2014, 06:54:19 PM »

Looks like I got the easy parts done.

Now moving to the left side.



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



Removed the rail, but WTF ??



More rust





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



Not much left



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



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 #130 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.



New parts I had already ordered.





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



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.



Disassembly has started.





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



Here it comes out.



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



Here is the housing cleaned and ready for paint.



And now painted with engine enamel.



More pieces to clean and paint.



Here it is, ready for assembly.



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



Hope to be able to assemble it next weekend, and then get back to the heater channels.
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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 #131 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.



Laying the whole thing at the side like this makes it so much easier to work on it.


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



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



Finally, the complete heater channel is out.



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



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



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.



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



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



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



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



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.



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.



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



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 #132 on: February 27, 2014, 06:45:51 PM »

can you powder coat my rims?

flat black!
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rothaus
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« Reply #133 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.
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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 #134 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!

Smiley

Gunny
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rothaus
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« Reply #135 on: February 27, 2014, 07:49:44 PM »

I got the blasting cabinet 4ft wide.



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.

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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 #136 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.



Some of the holes need some grinding





Finally they all fit.



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





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



A view from the outside, more holes to close.



Fabricating and welding in the new pieces.



Here it is welded in.



More small pieces welded in. Next is the outside.



The last hole between inside and outside is now closed.



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
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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 #137 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...
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-Paul
1990 k20 swapped Gti (3rd motor)
1985 merkur xr4ti (4th motor)
1989 6.0 lsx swapped k2500 (2nd motor)
2000 honda insight (1st motor... yay)
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« Reply #138 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.





A little cutting bending and grinding and it will fit.



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



More welding and grinding.





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



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



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



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



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.



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





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



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
« Last Edit: March 12, 2014, 05:44:53 PM by rothaus » Logged

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 #139 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



After treatment



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.





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



Now the oven keeps the temperature within 2 Deg F.

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



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



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




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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 #140 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.



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



So I cleaned them up a little.





Next Bead blasting and send out for yellowzinc plating



Here is what they look like when they came back.



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
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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 #141 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.



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

In process



And 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 #142 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



One more



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.



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.




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.







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:





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 #143 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


Cheers
Engelbert
« Last Edit: June 23, 2014, 02:11:22 PM by rothaus » Logged

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 #144 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!   Smiley
« Last Edit: June 22, 2014, 08:01:03 PM by whiteryder » Logged

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1998 BMW M3
rothaus
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« Reply #145 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.




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.



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



Not so good with the studs for the heat exchanger.







Got to drill them out.



I do it in small steps.



One done, 3 more to go.



So after the exhaust is out of the way and the studs all drilled out, it's cleaning time.



After cleaning it was clear that the oil return tube are the issue. The O-rings are flat.



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 #146 on: July 07, 2014, 05:58:52 PM »

Made some progress on my short term project:

Disassembled the front suspension.




Looks like we have some oil leaking going on around the oil cooler.



Scraping off the rough stuff





Front stuff is out







Top in the picture still the old original BOGE

Bottom with the new Bilstein Sport



Here all ready for assembly.



The protective shields were missing, so I got 2 new once.



Still waiting for the new bushings to assemble the A-Arms.



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.



The right one was a little bent, but I could get it fixed and powder coated it.



Talking about powder coating... never had a set of powder coated valve covers

Prepping them with Beadtblasting



And here it is.



The bottom as well, installed after the valve clearance adjusted, also the new oil return tubes are now installed.



Removing the old front wheel bearings. Wait when I got the hubs washed and blasted.



The weekend is almost over, but the rear shocks are installed.



Then it was time for a beer.

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 #147 on: July 21, 2014, 05:52:38 PM »

Made some progress last weekend.

Installed the new oil return tubes.



Blasted the heat exchangers cross-over pipe and the cat.

Heat Exchanger after blasting



After painting with VHT Flameproof silver



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



Here is the setup ready for installation



And here installed with all new nuts.







Moving back to the front suspension, hubs are all cleaned up and ready for assembly.



New rotors installed and ready for the bearings.



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.



Here they are, cleaned, coated, and ready for assembly.



A few more pieces to poader coat.



Assembling the front end.



here is the before picture



Here it is coming together



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
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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 #148 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.



Somebody installed some stainless brake lines which did not fit, and some hardware was missing.



So I got new once and also the herd lines to the caliper, since I couldn't get them removed without screwing them up.



Installed all the good stuff, and it looks good.... at least to me



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.



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.



This worked like a champ and all looks good now.

Just one thing, If you do this, block off the little overflow line.



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 #149 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.



I removed the bumper, tail light, and reflector to clean up the section.



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.



I took that opportunity to take the car out, jack it up and get it cleaned with the power washer... LOL Powa again.



Back on the lift and ready to put it all back together.





The tail lights needed some cleaning and the wires got a sleeve.






The tail lights lenses had the black paint peeling off.



I cleaned them and re-painted the black.



It's coming together, the bumper adjusted.



Bumperettes (or Stostangenhoerner) are on.



The license plate light were also junk, so here the new once.



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.



The rear end is back together.



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.



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.



Things look pretty ugly.



OK, lets do it, things come apart.



Drilling out the rivets from the seals.



Hi -tec support



This is almost like Overhauln just this is a one man show.



Here we go, the top is gone.



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.



Disassembling the rear section of the top.



More glue to remove... I hate this.



After cleaning the inside, after removing the old carpet and insulation, I painted it.



Time to put in the sound insulation.



I used rattle trap. Really good to work with.





OK, back to the top for a little bit.



Putting new foam and vinyl on the rear bow.



Here is it done, just need to punch it the 3 holes for the bolts.



Next, sorting out the new carpet.



It's Sunday late afternoon and time for a beer.

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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