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Chief
Indianapolis


Joined: 16 Sep 2010
Posts: 2475
Location: The Middle lands


PostPosted: Tue Jan 27, 2015 10:01 pm    Post subject: Reply with quote

Phil,
Tremendous progress sunshine. I'll drop over at the weekend and see how your getting on....(if the kettles on)
 
  
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LMR
Silverstone


Joined: 08 Mar 2009
Posts: 131



PostPosted: Tue Jan 27, 2015 10:38 pm    Post subject: Reply with quote

Kettle is always on. Might be on an epic adventure on Saturday with Gavin, so check before you waste a trip - will be around on Sunday
 
  
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steve baker
Nürburgring


Joined: 15 Nov 2011
Posts: 378
Location: Essex, UK

2007 Porsche 997 Turbo

PostPosted: Wed Jan 28, 2015 3:42 pm    Post subject: Reply with quote

LMR wrote:
Right, a quick update before taking a break for a few days - the potting shed is freezing and I have somehow forgotten to order a part, so I have had to change plan (or am I trying to kid you I have a plan here...) And I am full of cold, which just won't shift

Anyway, if you flick back you will know the rear bumper bar was a bit of a mess. The pic below shows what a bit of blasting and powder coating can achieve



I didn't enjoy removing the rivets when stripping this, and the rivets are an odd size, so I decided to use what I feel is a better solution. I came up with rivnuts and bolts. A little over engineered and probably pointless, but it looks right.





And the finished article. Really not sure why I have pressed on with this bit - lots to do before this does back on.



Assuming I don't relent on my vow to have a few days of rest and recovery, Happy New Year!!


Where did you get the tool for inserting the Rivnuts ? Question
 
  
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LMR
Silverstone


Joined: 08 Mar 2009
Posts: 131



PostPosted: Fri Jan 30, 2015 12:17 am    Post subject: Reply with quote

Steve

I bought my rivnut tool from a local engineering company. I have just looked on ebay, there are hundreds available, suggest you pay a little more for silver line / draper.
 
  
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LMR
Silverstone


Joined: 08 Mar 2009
Posts: 131



PostPosted: Fri Jan 30, 2015 8:25 pm    Post subject: Reply with quote

Those of you with long memories will remember I sent my oil pipes off before Christmas to have the flexi pipes replaced - I must admit I had nearly forgotten about them myself.

Before they went away, they looked like this. The were not ruined, but given the state of other pipes, I felt it was worth doing.



They now look like this



I was delighted. I have always loved braided hoses Very Happy

So, as they were back, and I haven't got a shelf big enough to put them on, I thought I should fit them to the car. I wasn't looking forward to this, but they didn't take long at all.

New rubbers



And fitted



 
  
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LMR
Silverstone


Joined: 08 Mar 2009
Posts: 131



PostPosted: Sat Feb 07, 2015 10:44 am    Post subject: Reply with quote

I must be getting very enthusiastic - I did a short stint in the workshop on Friday evening - and it was blooming freezing......

I had forgotten to order a couple of pipes to connect to the oil tank, but those have arrived, and the photos below show them in.

Off to workshop now, hopefully more progress today......

Oil dipstick guide pipe



Guide pipe connected to top of oil tank together with new jubilee clips on the other pipes



and final pipe to bottom of the tank

 
  
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LMR
Silverstone


Joined: 08 Mar 2009
Posts: 131



PostPosted: Sat Feb 07, 2015 8:18 pm    Post subject: Reply with quote

Just back from the freezing workshop. Reasonable progress today. I did the job I have been dreading, the sunroof seals. After faffing around this morning trying to convince myself I could find other things to do I finally gave in and gave it a go. The theory is very simple, put contact adhesive on both surfaces, live it a few mins and pop them on. I was putting it off as it is one of those fiddly jobs that could go wrong pretty easily, and I have heard tales of ruining the strips and having to buy mote. As with most parts, that is not a cheap process.........

Anyway, in for a penny and all of that.

Contact adhesive on the seal



And some more on the panel



Some time and patience later....



So with the "easy" bit done, I then did the one on the car.

A photo just to prove I do some work



The masking tape was to help keep the seal in place. I then popped a heater into the car to help with the drying process. As I left the workshop I had a look. I am very happy with the result, especially as I achieved it first time. I will upload a photo next time I get to the workshop, I think my fingers had given up working today. Did I mention it was cold?
 
  
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Chief
Indianapolis


Joined: 16 Sep 2010
Posts: 2475
Location: The Middle lands


PostPosted: Sat Feb 07, 2015 8:31 pm    Post subject: Reply with quote

I can vouch for how cold it is in the potting shed having just got back from seeing Phil. He is doing some fantastic work on this car. And the paint just looks soooo good Thumb
 
  
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DRZ911
Suzuka


Joined: 13 Mar 2013
Posts: 1117
Location: Belfast


PostPosted: Sat Feb 07, 2015 10:18 pm    Post subject: Reply with quote

A fantastic build thread - attention to detail is impressive - amongst the very best on this Forum. Laughing Laughing

Would be interesting at the end to get a total cost for parts, materials, sub-contract work and labour hours. Question
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991 Gen 1 C4S PDK Carrara White
Yamaha R1 and BMW R100RS
 
  
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LMR
Silverstone


Joined: 08 Mar 2009
Posts: 131



PostPosted: Sun Feb 08, 2015 12:00 am    Post subject: Reply with quote

DRZ

Thank you for your kind words, deeply flattered. My drive to replace parts is from being too lazy to keep going back and redoing stuff (!) and also I get frustrated when stuff doesn't fit. I used to compete in single seater racing cars. I learnt over the years that attention to detail was very important. Proper nuts and bolts make maintenance and reassembly much easier. Ropey old bolts are not as easy to work with or as safe as new stuff.

Price wise, I am deliberately not adding it up as I go along. I want my car to be the best I can achieve, and I have a view of long term ownership. It is nearly six years since I bought this car, and view this as long term ownership. It might seem belt and braces to have brand new components stripped and powder coated, but it will make maintenance so much easier in future.

I have taken a pragmatic approach on sourcing parts. I have spent far more at the OPC than I thought I would, but again, I know their stuff will fit, and the service / advice is brilliant. I also live near my OPC so that helps. Part of the pragmatic approach is to buy genuine parts where it matters, but not be a slave to it. For example, I have bought genuine driveshaft bolts, and will use genuine fixings for bodywork fixings, but a majority of the fixings I am pulling back on the car are high grade stainless steel sourced elsewhere rather than standard bolts from the OPC .

I haven't added up the hours, but will attempt to at some point
 
  
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LMR
Silverstone


Joined: 08 Mar 2009
Posts: 131



PostPosted: Sat Feb 14, 2015 10:48 am    Post subject: Reply with quote

Morning all. I took a day off work yesterday to get on some progress. I bought the 24,000 service kit a while ago but have been putting it off until I could sneak onto my mates ramp. It became free yesterday, so I no longer had any excuses.......

After scrabbling around the workshop, I remembered where I had left the box - and the fuel filter I had bought.



opening it up



A quick comparison of oil and new fuel filters. Not a terrible job to do, but you may need the skills of a gynaecologist to get at it.....



Shiny new air filter



And another shiny new oil pipe to fit



An unusual view of the car - you can just about see me underneath changing spark plugs



And talking a practical approach to turning the engine over whilst checking valve adjustment



Right, need to leave the comfort of home and go and finish off the 24,000 service......
 
  
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PeterS
Fuji


Joined: 01 Nov 2009
Posts: 9020
Location: Solihull

2003 Porsche 996 Carrera 2

PostPosted: Sat Feb 14, 2015 7:05 pm    Post subject: Reply with quote

Great stuff.

Slightly confused as to why you didn't just lower the ramp, rather than getting steps!

Confused
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Chief
Indianapolis


Joined: 16 Sep 2010
Posts: 2475
Location: The Middle lands


PostPosted: Sat Feb 14, 2015 7:11 pm    Post subject: Reply with quote

Great stuff Phil,
This thread just gets better with each post.
The Potting Shed is fast becoming a Mecca for all Porsche nuts Grin
I guess you haven't started on the valve clearances, as you still look like you have the will to live in the photos Razz
 
  
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LMR
Silverstone


Joined: 08 Mar 2009
Posts: 131



PostPosted: Sun Feb 15, 2015 12:26 pm    Post subject: Reply with quote

Pete

I was using the steps when doing valve clearances - easier to pop up and down a ladder that to keep sending ramp up and down..

Chief

Valve clearances done - that is an hour of my life I won't get back......
 
  
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LMR
Silverstone


Joined: 08 Mar 2009
Posts: 131



PostPosted: Sun Feb 15, 2015 7:59 pm    Post subject: Reply with quote

Quick Sunday update

Valve clearances done....



Valve covers back on - even correctly torqued - although I had to text Chief to get the correct torque settings



And all back together



Okay, I admit, not the most exciting update, but it is progress...
 
  
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LMR
Silverstone


Joined: 08 Mar 2009
Posts: 131



PostPosted: Sat Feb 21, 2015 7:22 pm    Post subject: Reply with quote

Another cold day of fiddling. Many moons ago I described the joyous process of removing the exhaust manifolds / heat exchangers. I was left with two broken studs. Various stud extractors, heat, more stud extractors and swearing still left me with two broken studs that refused to move. I ended up drilling up the centre of them and retreading the holes. Whilst this sounds simple, I can assure you it has been one of the most annoying tasks I have done in a while, with lots of broken drill bits. I think the low point was when, after completing the drilling, I broke a tap in the hole, then had to drill the tap out - resulting in more drilling....... frustrated

Anyway, I got there in the end.

Shiny new studs in place



And the shiny new oil pipe as well



And after some wrestling and wiggling, the manifolds back in place



As ever, these have all gone back in place with brand news studs, nut, bolts and gaskets.

Right, off for a rest - my arms and shoulders are knackered......
 
  
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Chief
Indianapolis


Joined: 16 Sep 2010
Posts: 2475
Location: The Middle lands


PostPosted: Sun Feb 22, 2015 4:47 pm    Post subject: Reply with quote

More good work there Phil. Your engine looks so clean. Well gell!
 
  
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Zingari
Donnington
Donnington


Joined: 25 Oct 2009
Posts: 11684
Location: Cheshire

1993 Porsche 964 Anniversary

PostPosted: Sun Feb 22, 2015 4:53 pm    Post subject: Reply with quote

What you doing about the engine tinwear Dont know That fibreglass option looks to be a good move.

Also out of curiosity where are the 'head studs' located as I know some engines have needed to be rebuilt just beacuse a head stud has broken what Are they the rusty looking one recessed under the valve covers Question
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LMR
Silverstone


Joined: 08 Mar 2009
Posts: 131



PostPosted: Mon Feb 23, 2015 5:09 pm    Post subject: Reply with quote

Zingari

Not sure which ones the head bolts are - I didn't find any broken bolts, and leaving engine internals alone until one day I shell out for an engine rebuild. Engine tins - brand new original parts, which have been powder coats. Probably fir those next week.
 
  
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Chief
Indianapolis


Joined: 16 Sep 2010
Posts: 2475
Location: The Middle lands


PostPosted: Mon Feb 23, 2015 6:45 pm    Post subject: Reply with quote

I'm guessing it must be bloomin cold in the Potting Shed Phil, there's a few typo's in your reply to Brian Grin
 
  
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