Turbo Engine Rebuild

[scam75]

Sounds a good job Thom, well done!


Pete, yeah I haven't been going mad with boost, the odd burst here and there. The turbo was rebuilt a while ago and looked perfect when it was all apart. It's still an old school turbo albeit with a larger hotside if I recall correctly............

Stuart

Nowt wrong with an old school Turbo Stuart, that's where the most fun is....??

Yes Pete, good point well made! As the car was intended to be, plus a few more PSI's for an even bigger reward after you patiently wait!

 

[scam75]

Well that's us hit 4,800 miles now and all is well, almost 12 months to the day it went back on the road (11th Sep). Oil still looks good and a nice colour, no leaks, no oil lost, no water lost. Going to wait till 6,500 miles before I change the oil, was changed at 500 miles after running in, so 6k is about the right interval I think.

Whilst the engine is seemingly perfect, of course the 944 has pointed me to other places to keep me busy, as it always will with a 34 year old daily driver! The infamous heater clip broke last week, on one of the hottest days of the year, hit a slight bump in the road and my glorious icy cold air instantly turned into a furnace! Lovely! On taking out the glove box, thankfully it was the usual suspect clip. A couple of tie wraps fixed it. Tried to order one from OPC on Monday, but you now need to but a pack of 10, still, £14.30 isn't the end of the world and I'll have 9 spare clips!

As noted in other thread, MOT passed with an advisory on a shock. Misty front shock coming off on Monday to go to GAZ for repair, and car booked in for 6th November to address a little bit of corrosion at bumper end of OS front wing, and a couple of minor paint issues.

Never a dull moment!

Cheers

Stuart

 

[TTM]

Well done Stuart. I hope your damper will be sorted in no time.
Have you tried to look check if something on the car could have caused it to wear out sooner than the others? It sounds strange to get the same unit to fail again.

 

[scam75]

Thanks Thom.

It is odd it is the same one, and no, I haven't checked to see if anything else could be causing the issue.

I had a good chat with Warren Gazzard @ GAZ, and he has promised to give it a very thorough inspection and have it fixed in a day for me. Could be the shaft is ever so slightly bent, he will check all that out and do what's needed.

I did have a hell of a fight with an ABS sensor on that hub not too long ago, maybe all the banging and thumping has upset the shock a bit? It's definitely a possibility. Anyway, it should be returned sorted quickly after a thorough inspection, Warren is aware this is the 2nd time the unit has leaked.

Stuart

 

[hotblack944]

Tried to order one from OPC on Monday, but you now need to but a pack of 10, still, £14.30 isn't the end of the world and I'll have 9 spare clips!

Hi Stuart,

I'll buy some off of you to ease the pain Happy to take whatever you don't need.

Cheers,

Jim

 

[scam75]

Hi Jim

No worries, can sort you out with a couple when they arrive.

Stuart

 

[scam75]

Not updated this for a while, funnily enough last update coincided with the OS front strut needing rebuilt, just as today saw the NS one make its way down to GAZ after suffering a similar fate. This repair will cost next to nothing, but its a pain in the bum. Anyway I've been promised a very good deal on a new pair of fronts if this happens again.

Oil service done the other day, now on 6,500 miles since the rebuild. Not a drop of oil anywhere and oil usage negligible, old oil contained no surprises. Had a small weep at the filter but the new filter has cured this. Also had a slight PS fluid weep at a pipe junction, this also now fixed. No coolant lost either with it sitting happily at max the full time.

So its full marks for all involved in the engine build journey so far.

As mentioned on other thread rebuilt a control arm ball joint today and in the process of bolting up a new brake set-up. New front flexis, recently re-conned M030 calipers with raised lettering in red/white, sebro discs, Mintex M1144 pads, OEM shims and new pad sensors. It will soon stop as good as it moves forward!

Stuart

 

[scam75]

Front end paintwork nearly done! Two wings needed some new metal, front leading edges and lower trailing edges. Bumper needed a repair, stone chip also done along both full sides and inside both doors checks has also been painted as was a bit tired. Will be the best she's ever looked. Should have her back before the weekend. I've also decided to give clear front indicators a go, although only because I had to buy a set to get new seals for the indicators which are not available separately. Can change them back to orange if i don't like them. I also had everything behind the front bumper tidied up and painted as there was the beginnings of some corrosion, so that's all done nicely as well.

I've also replaced a valance support as one was corroded (thankfully a bolt on part), and been able to replace the leaky washer hose which feeds the headlamp washers. Final touch was replacing the aluminium rear NS window trim which was corroded along the bottom with a fresh looking 2nd hand one I picked up.

Stuart

 

[PSH]

Looking smart Stuart....you'll have her ready just in time for the good weather..

Pete

 

[scam75]

Thanks Pete. Went down today, the stone chip has been done really well. Bumper needs another coat of paint so will be early next week now before she is home. He's also waiting on his window guy coming down to change over the rear quarter light trim.

And the lower valance support bracket (477 805 058 part number if anyone was wondering) was a pig to get off apparently. Needed cut off and washer reservoir removed as bolts were behind it. The water bottle needed removed anyway in order to replace the leaky hose. Thankfully this was all done without charge, I've come across a real gem of a guy up here and he has put a fairly large number of things right for me without adding to his original estimate. He is also very good at his job.

Not long now........

 

[dlknight]

Thanks Pete. Went down today, the stone chip has been done really well. Bumper needs another coat of paint so will be early next week now before she is home. He's also waiting on his window guy coming down to change over the rear quarter light trim.

And the lower valance support bracket (477 805 058 part number if anyone was wondering) was a pig to get off apparently. Needed cut off and washer reservoir removed as bolts were behind it. The water bottle needed removed anyway in order to replace the leaky hose. Thankfully this was all done without charge, I've come across a real gem of a guy up here and he has put a fairly large number of things right for me without adding to his original estimate. He is also very good at his job.

Not long now........

Ah that is the bracket that the power steering cooling loop attaches to?

Look forward to seeing the finished car!

 

[scam75]

Correct David, a bracket I never knew existed until my bumper came off! I needed the OS (driver) one, back order from OPC, no date. Of course the NS one was available next day from Germany for £18!. Bizarrely enough Gery @ Rare Porsche Parts had 11 in stock and he matched me a pristine silver one and chucked in the extra bracket with the plastic pipe holders, and next day delivery for £25, so I wasn't complaining at that. It seemed nobody else in Europe had one available, there were a couple on US Flea Bay. I have to recommend Gery and his service, wasn't aware of him previously.

Yes, I can't wait to get it back now, been away about a month...........

 

[blade7]

Seems like all it's birthdays have come at once. Is it a keeper now .

 

[scam75]

Indeed! I'd say after 15 years it's a keeper

 

[scam75]

Nearly there, i think the clear lenses don't look too bad, will see how I feel after a few weeks.......

 

[scam75]

Window trim now done, looking brand new! Just need the indicator and front fogs sorted now. I got a brand new indicator unit from OPC Glasgow for £150 inc. vat, the old one needed replaced anyway. They gave me a decent discount, arrives tomorrow morning. There is a spark coming out tomorrow to check the indicator and fogs. Not long.....

 

[scam75]

Bodywork all done, probably never looked this good in the 15 years I've had her! Annoyingly still at the garage awaiting the spark, new indicator unit dropped off (of course it came with a brand new orange lens........!). Definitely be driving her next week.........maybe......

Anyway, well chuffed with all the work. Both wings repaired, front edges and lower rear stone chip area, bumper repaired and painted, bonnet, nose panel and light covers painted, stone chip re-done along both full sides, inner door checks done both sides, rear quarter window trim replaced, front end under bumper tidied up and painted, hockey sticks re-bonded, sill trims refitted and looking straighter than ever, valance support replaced, leaky headlamp washer pipe replaced and a full valet.

Stuart

 

[PSH]

She looks great Stuart....very smart...

Pete

 

[graham.webb]

That's beautiful!!
Amazing shut lines, esp around the PU at the front.

 

[blade7]

That's beautiful!!
Amazing shut lines, esp around the PU at the front.

Well I wasn't going to comment, but it looks a bit low on the nearside and needs moving over to the offside slightly. Otherwise a nice job.