911 2.2E restoration

[Ferry Man]

Wonderful John. Just wonderful.

[JB-L]

Surely the best piece of bling is the DDK badge.................................?

[johnM]

Couldnt decide wether to put a repro bonnet badge on or this little beauty.

[210bhp]

Regards
Mike

[johnM]

Regards
Mike

Yep a big thanks to Mike who has almost donated this loverly piece of jewellery

[johnM]

Mike Bainbridge and my good self also rebuilt and set up my ZF limited slip diff today, calibrated to 45% should be great for road use.

Kind Regards

[Ferry Man]

this little beauty.

That is a beauty. Lovely condition. A fitting adornment.

[Mike]

Looking great John, you must be really pleased!

[johnM]

Gearbox today.

I bought a ZF LSD from DDK a little while ago, when it arrived it came with no output flanges and the diff casing was damaged due to somebody running the incorrect output flanges in the gearbox and also one of the Belleville washers that are conical had been home made out of a sheet of steel so it wasn’t very conical. Mike had the casing repaired and remachined and then rebuilt the diff with the correct parts. These LSD require a special longer output flange and they are almost imposable to find. After a bit of a search I came up with nothing so Mike suggested we use modified sun gears which will accept the standard output flange. Anyway today we pulled the old open diff out.



The ring and pinion look in good shape.
The ZF diff has been rebuilt with the correct parts and now is set up for 45% slip this should be fine for road use. Putting in various different thickness disc's alters the amount of slip the diff gives.



We tested the amount of slip with a torque wrench, you can see this is pulling about 50 lb/ft which equates to approx 45% (sorry for the poor photo)





You can see the back of the modified sun gears in this next photo. The fact I can use standard output flanges has 2 benefits one is that the flanges are plentiful and secondly they have probably had a much easier life that proper LSD output flanges. You can also see where the casing has been repaired and remachined in this photo.



Mike also pulled the rest of the box apart as I was complaining that it was a little difficult to engage 2nd, we unfortunately found an issue with 1st gear dog and 2nd gear sincro ring, anyway that will all get sorted before it goes back in.



Kind Regards

[johnM]

Wiring today

I have fitted and wired up the car today. The main loom is feed from the rear of the car forward through the tunnel, there is a conduit for the main loom and the heavy 12volt cable for the starter motor. I must admit I had no trouble feeding this in. I have wired the fuse board up as per wiring diagram again with no problems so far.





All the instruments have been wired up, it was a bit of a rats nest in there before the restoration but with a little planning all the looms went in and it became obvious where it all went, again the wiring diagram was bible. Looking at my photos I took when I ripped it all out, I would say that a couple of bits were wired incorrectly.





Not a bad days work..

[hot66]

you'll be finished by Xmas at this rate John

[JB-L]

Looking good!

[Darren65]

Great to see the gauges back in

Excellent work, well done.

[911hillclimber]

Lovely stage in any rebuild, the final assembly.

That shot of the gauges is so 911 it could not be any other car.(bit obvious I know)
Keep the big pics coming!

[58A - 71E]

should be just ready for the salt going down John at this rate, better pace yourself as you'll end up polishing and staring at it in the garage longing to take it out!