968 Crossmember dimension & Jakes refresh

frogisland · May 31, 2012

I'm trying to find a solution for my e9 racecar build and it may present itself via a 968 part. I'm trying to find the width of the gap on the 968 front crossmember where the wishbone attaches. It's the inside wall to wall dimension where the front wishbone & bush fit.

thanks
JP

jakerade · Jun 27, 2012

Hi JP I will measure mine for you as it doesnt have a lot attached to it at the moment!

Jake

JM1962 · Jun 30, 2012

I have a 944S2 crossmember on my garage floor at the moment and the dimension is 61mm +/- 0.5mm. The bush that fits measures 61mm across the metal insert faces measured with a vernier. The 968 and 944S2 crossmembers are the same part number. Hope this helps.

frogisland · Jun 30, 2012

thanks guys, appreciated. Jake...you should be ashamed of that! Also see my post re vapour blasting, might be of interest. ....a man of my own mind though...and to encourage you on:

jakerade · Jul 2, 2012

darn you JP........... Its a particularly frustrating project. I think you had the advantage of respraying at the same time?

frogisland · Jul 2, 2012

You're right, but still hugely satisfying once it is all together even with some of the patina of the original paint (my engine bay was not painted). The problem is keeping it clean afterwards. Very difficult to get a balance between using and maintaining that fresh look. Possible, but alot of work. Just make sure you use it without compromise afterwards, that's where most of the satisfaction comes from, otherwise it turns into a true garage queen. My e9 will be entirely satin black, shell and components, with the exception of the outer panels...makes keeping it clean easier! Keep up with posting photos though, some of enjoy seeing others efforts. JP

jakerade · Jul 2, 2012

i am thinking of using a clear dynawax coat on the wheel arches - i want to protect but also use it. There is a certain pleasure knowing the surface is good under the wax. On the undersides i have gone for a black wax as its grey'ish with all the protection removed. Lots of pics (Mainly for me to remember how it goes back together) here [link]https://picasaweb.google.com/108037537021429740964/UnderbodyTidyUp?authkey=Gv1sRgCIbzl-bantL1YA[/link] [link]https://picasaweb.google.com/108037537021429740964/HeadlightRemovalAndCleanUp?authkey=Gv1sRgCNLGovKswum0Tg[/link]

frogisland · Jul 3, 2012

Truly epic, many would call you (us) mad bastards, but it is hugely satisfying dismantling and reinstalling everything - just like a big jigsaw! You would certainly give me a run for my money...i like this one, been there, got into alot of trouble. Even had powdercoating in the oven and electro cleaning working away on the patio [

]

I can't even offer any advice, you appear to have everything covered, although there is always just one more photo you wish you'd have taken and a little guesswork comes into play. My e30 racecar went through the same treatment [

] (actually took the engine bay and wheel arches back to bare metal, then resprayed) http://smg.photobucket.com/albums/v384/frogisland/e30%20Build/?start=all

Looking forward to some photos of the assembled (and finished) item. Re the wheel arches, i found the bare paint was easy to keep clean once in a good state, wheels off every so often and thoroughly washed. I had the problem with rubber from the trackdays under the arches and along the side of the exterior but i suspect this won't be an issue. I took the front/rear PU's off and plastic wheel arch liners out after 2 years for a general reclean, easy weekend's work. I also used a great deal of stainless fastenings and fixings in areas not on general view and especially underneath - in particular self tappers. For 'Z' clips (the spring steel flat clips that self tapping screws go into) i found aftermarket ones corroded quickly, so generally bought repalcements from Porsche. JP

jakerade · Jul 3, 2012

Thanks JP I like the engine out picture. I have a 205 1.9 GTI which is going to get the full strip down treatment. I reckon its easier just to taken it all to pieces rather than fannying around. My project started with a headlight that wouldn't pop up! In then discovered a few oil leaks and got carried away!

Big Dave · Jul 3, 2012

Personally i think youve all got WAY way too much time on your hands......[

][

] Just kiddin.... Keep up the good work,, polishing and cleaning..... PS a car is for driving....[

][

]

jakerade · Jul 4, 2012

got the expansion tank in the dishwasher today - set it on timer so it can be ready before someone else gets home.........

jakerade · Jul 4, 2012

thought i would list some of the mechanical bits i have done so far in addition to painting things and making them generally nice... replaced sump gasket replaced balance shaft front and real seals and shells replaced oil filter housing gasket and seals replaced engine mounts replaced clutch master cylinder and hose replaced oil filler seals replaced wishbone bushes replaced front wheel bearings cleaned up headlight motor bushes Loads of other seals, bits and bobs and many parts refurbished. Going to publish a "greatest hits" gallery when i get time

vitesse · Jul 4, 2012

I am absolutely impressed-it gives a very good reason for not throwing away the old dishwasher when a new version replaces it as well-I suppose one of those -5 minutes for a quid -foaming hot car washers would help. Keep up the excellent work[

]

jakerade · Jul 10, 2012

latest update on my work copied from 968 UK Latest update Engine bay starting to come together now

Oil pipes and power steering pump on. I was going to replace the oil pipe but they are something stupid like Â£300!

Alternator has been rebuilt

Horns have come up well with a little bit of hammerite

Cleaned up inside wings before reinstalling headlights

Clear waxed the wheel arches with Bilt Hamber Dynax UC

Calipers looking rather good

Gave power steering cooler a bit of a spruce up

Wishbones and steering knuckles looking good as well

First headlight back in - remember, this is the reason all this started in the first place so slightly symbolic!

Oil cooler and power steering cooler

Wishbone and ARB back on - lots of lovely red grease courtesy of SuperMarv

And final one of the front and all the cooling pipes which have been test fitted

paulf968 · Jul 10, 2012

oooohhhhh blooming lovely ........ just had a most enjoyable 10 minutes drooling over the photos !! well done Jake

frogisland · Jul 16, 2012

Looking great Jake, some painstaking attention to detail. You get quite a buzz when you start putting it back together. Re things like oil pipes, you can have items such as these replated, or as a 'in the garage' solution, dip the ends in a solution of something like Bilt Hammer Deox-C: http://www.bilthamber.com/corrosion-treatments/deox-c Works very well, then Halfords etch primer and hand paint on some 2 pack black paint (or if you are particularly anal air brush a thinned down solution) Keep it coming. JP edited to add - Jake, have you seen this thread re a 205: http://www.pistonheads.com/gassing/topic.asp?h=0&f=47&t=1093997&mid=28907&nmt=My+1988+205+1%2E9+GTI+Resotration+thread

Fat Albert · Jul 16, 2012

I didn't realise that they had a power steering cooler!

jakerade · Jul 17, 2012

thanks guys some pics of stuff that has gone right..... new exhaust gaskets

lots of shiney stuff included my refurbed heat shield - I used silver bbq paint!

Another shot of heat shield

Almost got wheels

Suspension stuff - freed off height adjusters and bottom adjuster (quite a rare modification to M030)

I was going to repaint the dampers but the RAL paint i got is no where near a match so just did a bit of hammerite yellow touch up to get them through to the next rebuild. No I havent got over excited on the adjusters, thats white silicon grease!!

Debated elsewhere but this is the difference between after market bolt and the porsche one - its the bolt that holds the wheel to the car

Dampers sent to Ian Gardiner at IG Racing for a check over as something didnt feel quite right with one of them. Belts all on an tensioned although I did note in the manual it talks about the balance belt being positioned the correct way round with the coloured tooth facing the front of the car?