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Cat D Rebuild - More of the jigsaw completed!

Pauly, I don't think it's possible to really get the job done without getting the torsion tube out altogether and on the bench. Well, anything is possible. We used to fix some problems on site years ago because the facilities were not available but the E racing bushes are quite a job. Trying to drill the grease holes accurately is not something I would like to attempt on the floor. Also, if the tube and swinging arms are not polybushed, now is the time. I'm pretty sure you won't get the plates off without removing the arms and disconnecting your brake pipes from the arms where they meet the flexible pipe. Also the electrical connector on the body needs the earth undoing and the wires unplugged so you can drop them with the arms. As you lower the tube unclip the handbrake at the back in two places to give yourself more room. You must first wind off the hanbrake as far as possible in the cockpit and also inside the discs. Be carefull as the arms with discs and calipers attached are heavy. There is a guide on the Clarkes garage site. Big thanks to Jason who popped in this evening with the digital spirit level to asist with the spline issue. A much easier method of ride height adjustment without all the marking faff. Involves using the banana arm flat at its top as a zero then setting the long spring plate, that bolts to the swinging arm, to set the angle, in this case 10 degrees, by moving the inner and outer splines. Mine was at 16 degrees so no wonder it was out on the ride height We set it at 10 degrees, Big Dave are you listening[;)], with the height adjuster eccentric on the plates at the highest level after a bit of to-ing and fro-ing. Should give me some leeway to drop it if I need. After peering at it, it seems the plates have ended up at the original marks but the bars are definately not where they were. Won't know were it will be on the floor for a while as waiting for new polys as wrecked some others, not the usual purples, that were a bad fit re the steel inserts. Story there. Buy your purple polys from Stu. Again, big thanks to all the help from the usual suspects[:D] and the 944 guys and proves what a wonderfull facility this forum is. I'll set up a picture site this weekend so you can frighten yourselves over rusty pipes[:D] Cheers Dave
 
ORIGINAL: David Hooper Pauly, I don't think it's possible to really get the job done without getting the torsion tube out altogether and on the bench. Well, anything is possible. We used to fix some problems on site years ago because the facilities were not available but the E racing bushes are quite a job. Trying to drill the grease holes accurately is not something I would like to attempt on the floor. Also, if the tube and swinging arms are not polybushed, now is the time. I'm pretty sure you won't get the plates off without removing the arms and disconnecting your brake pipes from the arms where they meet the flexible pipe. Also the electrical connector on the body needs the earth undoing and the wires unplugged so you can drop them with the arms. As you lower the tube unclip the handbrake at the back in two places to give yourself more room. You must first wind off the hanbrake as far as possible in the cockpit and also inside the discs. Be carefull as the arms with discs and calipers attached are heavy. There is a guide on the Clarkes garage site. Cheers Dave
Thanks Dave, I've read 2 or 3 guides on how to do it the Elephant Racing one seemed the easiest, but after faffing about for the best part of a day it's time to at least disconnect the brake pipes and have one more try, if that doesn't work I'll do as you say and drop the tube completely. Paul.
 
Not a lot really. Just come back from Donington track so the sight of 968s spurring me on a bit. Waiting for polys for rear. Also re the spirit level method - ooeer missus - the plates need to be at the lowest ride height setting before setting the splines to get the 10 degrees measurement as mentioned. Then you can raise it as needed. Did adjust to the highest plate setting afterwards to see the difference. Was just under 16 degrees. While waiting have set about the engine bay with cleaning rag in hand. Got to the blower motor and found the pollen filters. They look original. Absolutely filthy[:'(] Can't have been any clean air getting through at all. Also under the windscreen area jammed with leaves and general rubbish. Soon be there. Definately pics set up this weekend. Cheers Dave
 
Trying to sort out pics onto p/bucket. Set up account started downloading pics. Was a little perturbed by the amount of ad hits on the site must admit. Then my session shut down because of unauthorised programs trying to get onto the computer and into windows systems. I run firefox and it's usually pretty switched on with stopping crap. Little bit twitchy at the mo as Di's laptop was completely kn******d by a vicious virus while in the USA. Any advice much appreciated. Cheers Dave
 
This may work[&:] [link=http://s792.photobucket.com/albums/yy205/594DPH/]http://s792.photobucket.com/albums/yy205/594DPH/[/link] Should have taken a few more really looking at it. It's going back together this week. [:)][:)][:)][:)][:)][:)][:)][:)][:)][:)][:)][:)][:)][:)] Have fitted the powerflex now, after the other rubbish, seem a bit harder than the set I had on the old CS a few years ago and are black not purple now. Hopefully lined up some konis soon but the front suspension will have to wait. Have to find decent digital radio/CD, any thoughts appreciated. Also better seats as the old ones are saggy. Thanks for everybodys support and comments. Cheers Dave
 
Finished pics here: http://i792.photobucket.com/albums/yy205/594DPH/Black968004-1.jpg http://i792.photobucket.com/albums/yy205/594DPH/Black968005-4.jpg http://i792.photobucket.com/albums/yy205/594DPH/Black968006-3.jpg http://i792.photobucket.com/albums/yy205/594DPH/Black968007-3.jpg Went for the subtle decals as its a road car really not a 'ring weapon[;)] Set the ride height at 635 to w/arch after experimenting a bit. Set at the lowest it was 620, then adjusted to highest it sat at 665. So there is a 45mm difference on the eccentrics at the plates. Also adjusted the throttle stop as last time out when MOT'd I didn't seem to be getting full throttle and was on the floor mounted stop rather quickly. Jammed the pedal down, went to check and sure enough still about 10mm play before the throttle was fully open. Felt much better after adjusting[:)] Went for a spin and it feels very nice. Not harsh at all. Can recommend the Elephant Racing bushes if you get to do the rear suspension and find the rubber and plates in a bad way. Have some 15mm spacers to fit yet and of course some Konis to find. Need better seats, have my eyes on some at the moment. It's been quite an experience but I'm just glad to be back in a 968 and pleased a perfectly good car didn't end up scrapped. Cheers Dave
 
Good job Dave, I ran out of time and motivation so didn't reindex my bars, my car is sitting at 650 mm with the plates on the lowest setting, maybe I will be keen enough this winter to pull the tube and drop the rear 15mm or so.
 
Dave. Finally its on the road... Looking good, nice + "stealth".. Although,,, "anal hat on". I think the CS decal font is wrong....Sorry...[8|][8|] The link i sent you the other day IS the correct font....
 
Hi Dave Great to see the car in the flesh last night at the club meeting, It looked very good, I know there are a couple of niggles but I'm sure they will soon be sorted and the graphics has just the right impact. Congratulations on the rebuild. Hope you like the vid of Dave. See you soon. Mike
 
Mr.Hooper the 968 looks very nice, job well done squire! Mike the photos you took at Doni were ace [:)]
 
Cheers Mike, the niggles sorted today. The terrible howling from the passenger door was an alignment problem. I think the paint lads may have taken it off when fitting the front wing. Unbolting and trial and error on the hinges and catch plate until I could hear that certain shut sound that 968 doors make, had it sorted. The ride heights are the same on level ground but the passenger side rear has no camber as not aligned yet so slight catch on the w/arch with the 15mm spacers. To be sorted next week at Zentrum. Now all I need is some good polish for black paint as it's starting to drive me bonkers already[;)] Cheers Dave
 
Dave. Im sure you dont need reminding NOT to use the Auto Glymm stuff.. As its mainly chalk, + leaves a white residue...
 
Glad you told me that Dave! A customer in the village who wrote her XK off through a hedge a few weeks ago, thanked me for sourcing her a replacement - this time an XKR which I hope lasts longer than the XK - by giving me a pack of Autoglym products yesterday[:D] That might be going to the Xmas box for some lucky person[;)] Cheers Dave
 
Dave, I have had the same problem with white residue with the normal Autoglym products but they have introduced a new High Definition wax, which is fantastic. We now use it on all our dark coloured cars at the garage. It is not cheap ( I think we pay 25 trade) but gives a real deep shine.
 
Thanks Kev, I'll look for that. Some of you may have noticed my wanted ad for a set of Koni shocks as a good road going set up for this car. As usual had some great replys culminating in the purchase of a complete set of 944 Turbo adjustable Koni's, new, unused & still with the Porsche parts stickers on, ready to bolt in from Tom - homesea on the forum - today. Big thanks Tom. The part no's tell me they are 944 M474 according to the Porsche PET. I'm sure someone will be along to tell me what that means soon[;)] Adjustable from the top on the front, bottom on the rear, but not with the threaded body for spring height adjustment as per the M030. They are quite a large diameter. Have bolted on the rears this afternoon after giving them one turn and they are great. Just firm enough without the harshness. Am now ordering bushes for the front as really want to get those shockers on so.............the front suspension rebuild starts this week[:D][:D][:D][:D] Cheers Dave
 

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