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Chief
Indianapolis


Joined: 16 Sep 2010
Posts: 2474
Location: The Middle lands


PostPosted: Thu May 16, 2013 1:57 pm    Post subject: 964 Project - 'The Red Baron!' Reply with quote

Well as some of you good people know, I purchased 'The Red Baron' just before Christmas. PeterS and I had a whizz around Oulton Park and managed to spin at the end of the main straight. This lead to us questioning the brakes (ABS pump, sensors etc..). I decided to start by cleaning up sensors and various earthing points in the luggage compartment. So to get started I thought give under the arches a good clean so I could see what I was doing...

After a few hours getting soaked, I was staring to get somewhere.

Some tyre rubbing but it is lower than a snakes belly!
Cleaned all the ABS sensors and that's when it started to get out of hand.
You see, when I reconnected the battery I had an alarm screaming at me from somewhere in the scuttle area. This would be fine if I had a remote control to disarm it Surprised well cutting to the chase I have now removed from the wiring loom 4 separate alarm systems! I guess as each broke an new one was installed leaving the old one too it's own devises...
So I ordered the correct loom tape from Germany and basically spent a month re soldering and replacing quite a large part of the loom. To do this meant taking out the Roll Cage, seats, carpet and a lot of the dash.


Now whilst I was at it I thought maybe I could get the trim modified to remove all the seat belt exits from the rear parcel shelf and rear quarter panels (More of this later).......
Anyway, we were looking at the brakes but got somewhat side tracked Grin Well the calipers took some time to identify as the faces had been machined off (I guess to make them look more modern). After some considerable effort (Thanks to Boxey, Thomas from Porsche Calipers and a few others on Rennlist) they are now identified as C2 fronts with 993 C4 rears. Anyway I digress...

I removed the said calipers and spent nine hours removing the pad plates!

And bleed nips!
I ended up with a rag tag collection of brakes to go over to the blasters.

Popped them over to a good friend of mine who lives for painting Razz

So onto the back plates, handbrake shoes and cables.

The damage from the track spin was next. The front jacking point had been smashed clean off and was embedded into the side skirt. So let's get the welding kit out.







Now fixed and in top coat.
Next was to paint the rear arch which had been rubbed by the tyre during the 'Off'

Then I noticed that the oil thermastat was looking very cruddy.

Now the more I looked the more I saw, so oil tank out



Fortunately no rot behind. So onto removing the crud and paint from the tank.


Right, this as far as I have got at the moment, I have ordered two of the biggest spanners to remove the oil pipes (32 & 36mm Zombie Bashers). If they turn up for the weekend I will be crossing my fingers that I can remove the corroded pipework (They are as rusty as Sponge Bob's door knocker!) and remove the front oil rad as it looks like it's took a bash in the spin. I don't mean to bore anyone, I know a few of the guy's on here are doing something similar, but a few people have wandered where I've been. I will carry on adding to this thread if there is interest. If not I'll carry on quietly bashing at the Barron.
bye

Last edited by Chief on Sat May 18, 2013 7:46 pm; edited 2 times in total
 
  
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Vic
Montreal


Joined: 03 Jun 2003
Posts: 608
Location: Surrey


PostPosted: Thu May 16, 2013 5:05 pm    Post subject: Reply with quote

Keep posting Chief Thumb

It's great to see this kind of work being done. If the weather ever improves, I might even tackle mine Floor
 
  
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Zingari
Donnington
Donnington


Joined: 25 Oct 2009
Posts: 11664
Location: Cheshire

1993 Porsche 964 Anniversary

PostPosted: Thu May 16, 2013 5:10 pm    Post subject: Reply with quote

Chief - Keep going Thumb Some areas of work for me to do as well. The nuts on the oil thermostat must be shite as mine are as rusty as the hinge on Pete's wallet nooo I will be replacing those parts as well.

I suspect the spin may be the extra weight of 4 x alarms not being evenly distributed has thrown the car out of balance Dont know

What the heck did the jack point run into Dont know
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apw2007
Zolder


Joined: 29 Apr 2008
Posts: 5804
Location: Surrey


PostPosted: Thu May 16, 2013 5:12 pm    Post subject: Reply with quote

It's a slippery slope but at some point it needs doing! Thumb
 
  
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SausageCreature
Barcelona


Joined: 10 Jul 2011
Posts: 1444



PostPosted: Thu May 16, 2013 6:40 pm    Post subject: Reply with quote

Nice, but begs the question "Do you have too much time on your hands?"

Mark
 
  
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Zingari
Donnington
Donnington


Joined: 25 Oct 2009
Posts: 11664
Location: Cheshire

1993 Porsche 964 Anniversary

PostPosted: Thu May 16, 2013 6:48 pm    Post subject: Reply with quote

You could ask Pete's mechanic to get on with it Floor

BTW - Lose the silencer and fit a G-Pipe. You must have the quiestest car on track wack
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sparky1pq
Spa-Francorchamps


Joined: 16 Jul 2011
Posts: 290
Location: North West

1996 Porsche 993 Carrera 4

PostPosted: Thu May 16, 2013 7:47 pm    Post subject: Reply with quote

Excellent thread, keep posting.
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sjl178
Monza


Joined: 18 Dec 2009
Posts: 230
Location: Melton Mowbray


PostPosted: Thu May 16, 2013 9:09 pm    Post subject: Reply with quote

Absolutely brilliant work so far Thumb please do keep the reports and pics coming.
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Waz
Paul Ricard


Joined: 14 May 2011
Posts: 3493
Location: Sutton coldfield


PostPosted: Thu May 16, 2013 9:28 pm    Post subject: Reply with quote

I know it's a 964(yawn) having seen it in the flesh so to speak it is quite interesting keep up the good work in you heated decorated garage Grin
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Chief
Indianapolis


Joined: 16 Sep 2010
Posts: 2474
Location: The Middle lands


PostPosted: Thu May 16, 2013 10:06 pm    Post subject: Reply with quote

Thanks for the encouragement guys. I will post more as soon as I've made progress.

Sausage wrote:
Nice, but begs the question "Do you have too much time on your hands?"

Mark

Mark, you are properly right! Embarassed
 
  
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Chief
Indianapolis


Joined: 16 Sep 2010
Posts: 2474
Location: The Middle lands


PostPosted: Thu May 16, 2013 10:07 pm    Post subject: Reply with quote

Zingari wrote:
You could ask Pete's mechanic to get on with it Floor

BTW - Lose the silencer and fit a G-Pipe. You must have the quiestest car on track wack


Brilliant Brian, as always mate.....poor old Pete Floor

Re the exhaust, it's de catted and the box across the back has gone.
It's running at 106db !!
 
  
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Porsche964FP
Trainee


Joined: 21 Jan 2011
Posts: 92



PostPosted: Thu May 16, 2013 10:12 pm    Post subject: Reply with quote

Great work - well done. Smile
 
  
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KP964
Kyalami


Joined: 20 Feb 2012
Posts: 1966
Location: Northumberland


PostPosted: Thu May 16, 2013 10:15 pm    Post subject: Reply with quote

I was going to put up a similar thread but it seemed a bit pointless as i was only removing my air filter Grin .
Nice job Chief , mine is under investigation at the docs at the moment .
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Porsche News
Motoring Editor
Motoring Editor


Joined: 08 Feb 2008
Posts: 6913



PostPosted: Fri May 17, 2013 12:17 am    Post subject: Reply with quote

Chief wrote:
Thanks for the encouragement guys. I will post more as soon as I've made progress.

Sausage wrote:
Nice, but begs the question "Do you have too much time on your hands?"

Mark

Mark, you are properly right! Embarassed


Great thread, all that sunshine! perfect weather for working on the 964
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PeterS
Fuji


Joined: 01 Nov 2009
Posts: 9019
Location: Solihull

2003 Porsche 996 Carrera 2

PostPosted: Fri May 17, 2013 1:03 am    Post subject: Reply with quote

Great thread, but doesn't start to do any justice to all the work and hours Chief is putting into this.

His story is only scratching the surface.

This car is going to be the dogs wotsits.

worship worship
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Chief
Indianapolis


Joined: 16 Sep 2010
Posts: 2474
Location: The Middle lands


PostPosted: Fri May 17, 2013 8:54 am    Post subject: Reply with quote

Porsche964FP wrote:
Great work - well done. Smile


High praise indeed Frank coming from the creator of BB thank you. I have followed your various threads on Rennlist. Much respect due. I just hope I can get in the same ball park Thumb

Everyone else, thanks for the encouragement, and Pete is over egging the cake a bit (but thanks old pal) It's not a case of the satisfaction in doing a job yourself, honestly. It is a case of Porsche being robbing you know what's I have to have a crack at it to save some squeelers!

The trim does look fab, if I say so myself. I hope when it's in I can get some pics that do it justice. The RS door cards are a thing of beauty. Trying to get across to the trimmer that I wanted grainy leatherette that matched the door caps was fun. He couldn't understand why I wanted it to look '90's' and not have sooooper smooth modern leather Grin to hide it's age.

Still lots to do, and the pace really is dictated by how many times I have to heat everything to get stuff off the car.

Again, thank you all for the encouragement and I hope to do this classic shaped beauty justice.....Stay tuned bye 'The Baron'
 
  
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PeterS
Fuji


Joined: 01 Nov 2009
Posts: 9019
Location: Solihull

2003 Porsche 996 Carrera 2

PostPosted: Fri May 17, 2013 10:40 am    Post subject: Reply with quote

You are too modest.

Your car will be immense.


Open Youtube Page


Thumb
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paul284pt
Albert Park


Joined: 16 Sep 2010
Posts: 1547
Location: North Yorks.


PostPosted: Fri May 17, 2013 8:46 pm    Post subject: Reply with quote

Excellent work worship

Keep the pics coming.

Good luck,
Paul
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Tim Richardson
Hockenheim


Joined: 30 Jan 2007
Posts: 646
Location: Surrey


PostPosted: Sat May 18, 2013 6:29 pm    Post subject: Reply with quote

another 964 getting the treatment...top stuff Thumb
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Chief
Indianapolis


Joined: 16 Sep 2010
Posts: 2474
Location: The Middle lands


PostPosted: Sat May 18, 2013 7:02 pm    Post subject: Reply with quote

Ok fellas, today has been a bit of a slow one...
Lot's of chores around the house to do so i've only done a little bit.
I started by removing the top tube from the oil tank. This is the one that the dip stick lives in. Again the use of heat the only way to remove nuts that have been sat there for 23 years. Also there was the bottom bracket to remove the captive nut from.

Then it was time to move onto the thremastat and clean it up to stand a chance of attacking that monster nut


Now the frightening thing I noticed was when I twisted the bottom rubber hoses around to have a look. One has a split along it's entire length Surprised

Good job I caught that one before it let go!
So then onto the oil radiator. This as you can see is an oily mess

Now I think the culprits here are the top fittings. I can rotate the pipes around on their metal pipe ends. This I don't think is how it should be. I guess the rubber has gone hard and under pressure are misting the oil over the rad.


You can clearly see the pipe ends are covered with oil....
So I have been spraying the rad on and off all day with Gunk to try and clean everything up a bit to be able to work on it.

So that is pretty much it for today. I did manage to clean the 996 though. Razz

So lastly I have just found a couple more photo's of the brake rebuild

Blasted and ready for paint

I shall try and get at least some of the Pistons and seals in tomorrow.
Well that's me for now. I hope you are finding all this entertaining Grin
The Red Baron will rise again.....
 
  
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