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Author Topic: My Garage Build - The Airboxer Garage  (Read 115967 times)
rothaus
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« Reply #200 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.



Here some of them done



Also did the pedal cluster.

Here the before





Here after the pan piece blasted and coated and with new bushings.



And ready for the time of installation.



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 #201 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.



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.



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.



Here is the new flasher relay installed , it's # 3 from right. They all look so happy now nice and clean.



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.


Here are they ready to get back on.


Next is the front spoiler, there were some cracks and on the right side it was broken out where it mounts to the fender.



I took it off and re-enforced it from the inside. That spoiler is paper thin.



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.



To be continued

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 #202 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.



The Banana arms are ready, bushings and bearings are in.



The Steering rack is assembled, I decided to go with the Turbo tie rods.



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.







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 #203 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.


Inside the garage and ready to on the lift.




I just finished some details for the trunk and under the car.

Here some pictures.
















Also restored the engine shraud, so it's ready when ever I need it.



Still waiting for some bits and pieces for the suspension, so I can mount it and get it on the wheels.

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
jloehlein
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« Reply #204 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.

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rothaus
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« Reply #205 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







Here are some of the rear brake components restored.



Here more rear installation.





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 #206 on: October 14, 2016, 05:58:26 PM »

Here are a few more pictures how things come together.



Starting the front suspension



Steering linkage is in as well.



Struts are in.



T-Bars installed.





Struts are in.



A little bit of rear drum brake hardware porn. All restored.



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.



I started to sort out and install the Frunk wire harnes



Fuse box installed, still some wires to sort out



More to sort out for the Dash section.



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 #207 on: October 20, 2016, 07:13:48 PM »

Very impressive, Englebert. It will really cool to see the final result.

David
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rothaus
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« Reply #208 on: October 23, 2016, 09:25:33 AM »

Thanks David

Continuing on the trunk wiring.

Nice to have today's technology.



Most is sorted out, the instruments will come in later.



I started to prepare the ventilation system



Need to be disassembled, cleaned and see if anything need repaired or replaced.



Since this was never disassembled the dust is all there.



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.



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.



All the plastic pieces and metal are in great shape and look like new after cleaning.





However, the plaps and linkage I will restore, and put a new seal on it.





The brake line set came in, so I installed the long line in the center tunnel.







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.



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 #209 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.



Made new seals from 4mm foam sheet



Test fit it.



Also plated the little clips which hole the fan housing together.



The fan housing is complete now with new motor and fan.





Here it is, ready for the car.



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.



Timing chain housings are off.



Heads and cam housing ready to come off. All head studs where in tact.



Cylinders are ready to come off.



Here the parts, damn, a lot to clean.



The cylinders and pistons are removed and the head studs are next.



The studs came out without fight, I only used 2 nuts.



The casing is open.



And the crank shaft is out.



Here it is.



I found that the last 2 rod bearing have some wear, Cyl # 3 and 6.





I also took the heads of the cam housing and removed the valves.



Will continue soon, now I have to clean all these parts, so I can inspect them.

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 #210 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.





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.



Here is the area that need repair


Cut out the bad section


Fit the new piece


Weld it in


Clean up and done



Got it primed and ready for final sanding and painting.



Here they are now painted.



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.



I did not expect that it will become such a project.



After seeing this, I started to dig in and get the body filler off.



Oh boy, somebody did some hi-tech repair.



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.



It was not as bad as at the rear end.



There were 3 holes when somebody tried to pull it out, so I welded the holes and massaged the rest.



While I was on it, I welded the side marker hole. I never liked the look of them.



I was pocking around in the rear trunk and found 2 areas which looked suspicious.



There were some small rust areas which were masterful repaired with body filler.



After removing the material it showed 2 sections which need some attention.



I removed the exhaust heat shield below.



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.



A view from the bottom side.



Here I have the sections cut out.



I made new pieces to be welded back in.



Here they are welded back in. Pardon the ugly welds, I will clean them up.



Here is it cleaned up.



Another view from the bottom side, with the heat shield support welded back on.



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 #211 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.



Careful removed the spot welds



I found a small area which needed a little patch.



While I was fitting the new piece, I also made the patch.



One more small section to be fixed at the bottom, but no big deal.



Here it is, ready to get welded in.



I prepped the section of the car with some primer, chip guard, and paint, on the section, I cannot get easy later on.



Here is the new panel complete welded in.



Here is what it looked before.



With that I moved to the front bumper section. When I removed the trunk seal, I found some additional section, which need some repair.





OK, cutting out.



Welding in.



More pieces, this was above of the headlight cover, hidden under the trunk seal.



I painted that section for now, so I can concentrate later for the external section.



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 #212 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.





Ready for assembly. Now I looks at these parts and need to do something. I cannot install it as is.



I got the Headlight supports Powder coated. The most work was to get them all clean blasted.


Installed




Front Bumper is mounted.


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.



Getting the rear side ready.


Bumper is installed.


Just need to find a nice plate holder and a plug for the hole.


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

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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 #213 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!!
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(And 38 others that I have owned and loved over the years)
rothaus
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« Reply #214 on: January 06, 2017, 08:07:21 AM »

Getting back on the 911.

Started sorting out some items and blasted the Cylinder cooling sheets.



And powder coated them. One is missing in the picture. That need some small area repaired.



Small stuff, but there will be more progress coming up soon.

Happy New Year
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 #215 on: February 20, 2017, 07:04:09 AM »

Here is a little update:

I started to clean more engine parts. No comment needed.















The parts not seen in this picture will be stripped and plated










I started to take a look at the seats.


The hinges looked pretty rough.


But I was able to clean them up.


Taking the seat bottom apart.




I think I will need to find replacement for the old horse hair stuff and replace it with some foam.



I also want to find a way to make the seat bottom a bit more firm.

That's it for today.
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 #216 on: February 23, 2017, 03:43:40 PM »

Continue on the disassembly of the seats.



These seat shells are not painted from the factory. I think they never expected these cars last that long.



I cleaned them up a bit.



And gave them some paint.



I got a set of new covers on the way, as well the bottom foam.

Next the seat belts.



I hate when people put masking take on parts like this and then the tape stays on it for over 10 years or longer.



They cleaned up OK, and are ready for assembly.





The rear seat came out nice as well after some scrubbing.



I picked up some vinyl today, to recover the rear shelf and the rear side panels, knee pads, etc.

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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