Restoring my first 914

For all you Porsche 914 fanatics!

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Darren C
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Re: Restoring my first 914

Post by Darren C »

Nice try! :lol:



Today I picked up the freshly dull zinc plated wheel bolts. The pre blasting really did the trick and all the heads are now a nice even texture with no socket marks showing in the zinc plate. :)
All the old bolts are the same Kev, the new one is top row last one on the right.

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The dark rings on the thread is where they were wired up to hold them in the tank for plating. This will have a nice coating of copper grease so should be fine when fitted. :wink:
I’m really pleased with how they came out. It cost me a Tenner :) :) :) to get them done which is just less than the price of the one new bolt (which I needed anyway as I had a rogue Beetle bolt in there)
To answer your early question Kev. Yes ALL the old bolts have a VW stamp on the end. The new one doesn’t. :roll:

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Tonight after food shop and clothes washing I spent a couple of hours in my shed and started to turn down a piece of 316 Stainless bar.

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:)
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Darren C
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Re: Restoring my first 914

Post by Darren C »

Today with all the wind and rain I stayed in my shed and continued working on my lathe. I machined out two counterbores to an interference fit for two bearings I’d bought. I selected high temp bearings with steel dust covers to keep the grease in while exposed to engine heat. Next the flange was drilled and the bracket tapped M5 to hold it in place. :)

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This afternoon I turned down another Stainless bar to make a spindle. I incorporated a boss to sit between the bearings and run freely with 0.25mm clearance, so that if ever a bearing failed it would run on the boss rather than collapse.
To finish the ends were threaded M8 and two opposing flats filed accurately to accept the levers (yet to be made).
:)
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Darren C
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Re: Restoring my first 914

Post by Darren C »

This morning early on I went and picked my son up in the Traveller and we spent the rest of the morning out on more driving lessons. We went further a field today and did almost 100 miles. I am organising another club event (one of many) so on the way back we called in at the venue in Midhurst and arranaged a few bits and bobs for next year before setting off for home.
We had a pretty dodgy moment with my son waiting to turn right, just starting to turn and a Police car overtook us at a ridiculous speed. I was not best pleased :evil: a split second later and we’d have been completely wiped out!
Thankfully we stopped in time and apart from being a little shook up, we were unscathed. :roll:
Anyway, this afternoon I continued in my shed and made a top link arm with an off-cut of the stainless sheet. Very carefully filing out the slotted hole until it was a nice fit on the spindle I made yesterday. :)
Afterwards I carried out a dry run with a few parts borrowed off the worn throttle body (un-modified).
With the re-used spindle return spring it should give a “stock feel” to the pedal. I just need to make an anchor for the spring near the base and a cable fixing arm during the week and it should be good to go. :)

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Darren C
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Re: Restoring my first 914

Post by Darren C »

Today was a little frantic to say the least. I had a 10:15 hospital appointment in Portsmouth but decided to get up early and do a bit on the 914 very early on.
I’d picked the wheels up from the blasters on Friday and taken them home. The guy who works at the platers said he needed them pretty clean so that it wouldn’t contaminate his chemical tanks. The blasters had done the rear of the wheels as asked but the rims had lots of hardened black rubber marks from the tyre beads and the face of the wheels had old black and dirty stick foam from old wheel weights. All this had to come off before I could drop them off to be stripped of the original clear anodise coating.
It took me a good 2 ½ hours this morning to clean all this off with a combination of aluminium plate scrapers (I’d cut from some spare ali sheet) brass wire brushes, Cif cream (good olde Cif) and some pan scrubber scotchbrite (the green stuff that wont easily scratch) and a good amount of Cellulose thinners to clean after and remove the old grease from down and around the bolt holes
As it was a Monday and I’d had engineers working on a project at work over the weekend I needed to go into work before the Hospital appointment at 10:15. I had breakfast on the run, loaded the car with the wheels and shot off for 2 hours at work before leaving in good time for the Hospital.
I had an EEG test following my TIA last month, where they wire about 30 electrodes on your scalp to measure your brain waves, make you look at strobe lights and hyperventilate until you start to starve your brain of oxygen (all in the name science). :roll:
What they don’t tell you is that they measure and mark your head/hair with a pastel crayon then a sort of paste and glue the electrode onto your head, so by the time it was time to leave I had a head covered in goo, sticky stuff and spots of yellow pastel crayon. Not a good look and certainly gave me a few funny looks on the walk out of the hospital! :oops:
Anyhow, still looking like some crazy punk rocker I dropped the wheels off at the platters to get them stripped of the clear anodise before rushing home to wash my head.
After a manic wash and brush up I leapt back in the car, hair still wet and raced to Chichester Hospital for a 2pm MRI brain scan.
This was a novel experience too. Stripped of any metal jewellery, clothing containing metal and fitted with ear plugs and ear defenders, my head was sat in a cradle with a cage place over it while I entered the large donut MRI machine. This banged, clunked and buzzed in an alarming way for 20 minutes with me daring not move a muscle as it carried out an in depth brain scan.
Fun over I asked the lady where I collect the photo (in a sort of Alton Towers, end of the ride way).
Back in the Hospital carpark I turned my phone on and got a message to say the wheels had been stripped and were ready to collect. By now it was 4pm and a toss up between going back to work for an hour or picking up the wheels. Guess what choice my fried brain made…… :wink:

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They’ve come up like brand new! :shock: :)
Tomorrow the next stage of this refurbishment process is to go back to the blasters to gently blast the dull area’s between the polished petals to remove some old battle scars to give a uniform texture before going off to the polishers.
Once all this is done they can be re anodised in clear. I forgot to mention that when I dropped them off this morning before work the chap used a special meter on them to measure the original factory anodise thickness. This ranged from 8.5 microns on the face of the petals (which you can only presume wears thin with washing over 40+ years) to 11 microns on the inside of the wheel (under the tyre where it cannot get washed/rubbed)
The platers reckon they can get 20 microns on them when they re anodise, so hopefully this will exceed the factory finish and prove to be longer lasting. :) :)
With half an hour to spare after picking the wheels up tonight I raced across town and picked up some more nuts, bolts and metal bar from the ironmongers before they closed.
This evening I returned to my shed and made a spring anchor from more stainless to tie in the linkage return spring. While lying in the MRI scanner this afternoon I had the idea to use one of the threaded bolt holes in the bearing housing as a fixing point (which fell just in the right place for spring tension) instead of welding a tab on. Much neater idea, I thought, and also variable if required, unlike a permanent weld if I’d taken that route. :) I also made a stainless spacer/bush to go between to factory recycled throttle arm and my new dual arm (to replace the packing washers I'd used to help set the positioning up during design)

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As for the brain scans......they're still looking :lol:
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nrc914
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Re: Restoring my first 914

Post by nrc914 »

Blimey Darren, it tires me out just reading what you've managed to fit into today! Looks like you're making great progress and I'm glad you're on the mend.

Regards
Nathan

1975 914/4 1.8 (Needing Resto!)
2008 Cayenne GTS
1993 993 Carrera 2
1967 VW Beetle 1300 (In loads of pieces!)
914 KEV
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Re: Restoring my first 914

Post by 914 KEV »

All wonderful stuff Darren, watching the wheel progress with much interested.
Darren C wrote:carried out a dry run with a few parts borrowed off the worn throttle body (un-modified).
With the re-used spindle return spring it should give a “stock feel” to the pedal.
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Just like to point out one thing that you have missed understood about the fuel injection throttle body!

The spring you removed from the old fuel injection throttle body is not the throttle return spring! :wink:
The throttle return spring is long straight spring which mounts between the throttle cable outer sleeve mount on the intake air distributor and the throttle butterfly pivot on the top bar where the spindle spring is tensioned against.

The spring you removed is in fact a safety spring.
This spring was added onto the throttle body towards the end of the 74 model year.
If the throttle return spring failed, this safety spring would close the butterfly so the car would stop accelerating.
I’ve had a throttle spring fail before on one of my 914s, the engine will keep accelerating with the throttle butterfly fully wide open! Just a matter of turning the engine off and coasting to the side of the road, but there were incidents of accidents in the U.S. caused by throttle return spring failure.
914 Daily driver since 1990
Darren C
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Re: Restoring my first 914

Post by Darren C »

Thanks Nathan, I feel same as always, but just need to know what on earth caused the mini stroke. They wouldn't tell me if the EEG or MRI was good or bad yesterday when I asked afterwards; only that my consultant will arrange an appointment for him to discuss it with me shortly. I kinda figure that as they let me walk out, there's nothing to worry about unless I'm told otherwise.

Thanks Kev. I can see how that would work. As an engineer the “coiled” spring I have used is a far better design, made of thicker spring steel and generally resistant to weakness and failure than the other “stretch” spring you’ve identified as the return. I can see why they called the one I’ve used as the “safety” spring.
It’s a no brainer to use this spring in my new linkage as its much better suited. I’ve assembled and dismantled the original throttle set up numerous times now to aid the build of my new assembly and most of the work is done by the coil spring to return the butterfly to the closed position, the stretch spring really does look like bodge it and scarper engineering in comparison. :roll:
Great history information Kev, I’m not surprised in the slightest that they had issues with the early throttles with just a single spring!

Today I dropped the wheels back off at the blasters and explained what was needed on the “dull” area’s of the wheel faces, so hopefully they get out the numerous dents and scratches before February! :wink:
I had a few parts turn up in the post today including the majority of my 316 stainless pipe fittings that I plan to construct a fuel rail with. (This is the one I mentioned designing a couple of weeks ago). :)
This evening I spent a few hours fettling the top arm, drilled and tapped it and fitted the ball joints for the throttle rods. I also used another bit of Cornflakes box to inamgineer a nice looking bracket to attach to the assembly to anchor the throttle cable. Just need to pick up an off cut of 3mm stainless plate tomorrow to make it with.
The parts I removed from the old throttle body (arms, washers, bushes etc) I bagged up tonight ready to drop off at the platers tomorrow. I plan on getting the whole lot done in gold zinc (including the bits I’ve recycled on my new linkage plus those I haven’t) in this way at a later date when I invest in putting back the FI system, they’ll be all shinny & new looking. :)
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Darren C
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Re: Restoring my first 914

Post by Darren C »

Today I dropped off the bits of linkage at the platers and picked up some more stainless sheet from the iron mongers.
This evening in the shed I spent 3 hours cutting out and filed into shape the throttle cable mounting bracket. :)
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Darren C
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Re: Restoring my first 914

Post by Darren C »

It was an early start this morning as I needed to be in Bristol for work first thing. :roll:
After getting home late this evening I manage to mark and drill out the throttle cable bracket I made last night with several holes and fettle some 5mm stainless bar to make the linkage arms with. I also made two angle gauges to enable me to bend the 3mm stainless plates tomorrow at work to the exact angle. :)
I also had an M5 left hand thread die turn up in the post so fingers crossed I have the tools required now to make the adjustable linkage rods this weekend.
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911hillclimber
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Re: Restoring my first 914

Post by 911hillclimber »

Good going!
Did your car have these parts missing (I am not familiar with 914's) and why use St St when you have been so careful to originality elsewhere?

I loath working stainless, fights me all the way!
73T 911 Coupe, road/hillclimber 3.2L
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Darren C
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Re: Restoring my first 914

Post by Darren C »

These bits are just plain self-indulgence on my part. They’re a quality engineering solution and a “space holder” to run carburettors (which I have multiple spare sets in my shed, to get the car on the road) while the FI system is carefully restored.
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Darren C
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Re: Restoring my first 914

Post by Darren C »

I took the brackets into work this morning and used the bending press to shape them. I also called in at the platers at lunch and picked up the gold BZP replated original throttle arms, bushes, nuts and washers all looking fantastic shiny and new. :) A final call into the tool shop before going back to work and I picked up a small 13/16” die wrench for the LH thread M5 die I purchased earlier in the week to make the linkage rods. (My other wrenches are too large to hold the tiny die)
This evening I started to clean up the brackets to get some of the press marks out ready for assembly this weekend.
I also started on the new stainless fuel rail and made up the parts ready for Tig welding. :)
I should have enough bits to keep me going this weekend while the wheels are still away. I’ll take some pictures tomorrow of progress as I’ve not been home in daylight this week!
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911hillclimber
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Re: Restoring my first 914

Post by 911hillclimber »

I hope I will find such a good local plater here.

Have you cleaned the fasteners before delivery (wire brush etc) or just take a box full of fasteners and leave them there for BZP?

I have a load of fasteners from the Honda motorbike I'm currently restoring that all need stripping of old plate and crud then re-plating bright zinc (not yellow passivation)
73T 911 Coupe, road/hillclimber 3.2L
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Darren C
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Re: Restoring my first 914

Post by Darren C »

Re plating is only as good as the preparation. I usually remove all rust and grease as the platers won’t put anything dirty into their tanks as it contaminates. If the rust is severe then you need to think about having it polished out first.

Today I had a good day making stuff.
Since the weather was awful I spent the day in my shed and cut and treaded some stainless pipe to make up a nice fuel rail with centre feed so as not to starve either carburettor. To ensure that there was no risk of fuel leakage from any of the thread fittings, all joints got stainless Tig welded up.
To make sure all the welds and joints were good I capped the ends and pumped it up with my foot pump to 10 psi. (I plan on running between 3 & 3.5 psi, so a test at 10 psi is more that sufficient). To double check I submerged it in the bath for a good while and all went well. :)

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Next I turned down a fuel bleed/return. When running carbs with an electric pump it helps to have a bleed/return to keep the pump happy when the engine is at idle and the floats are closed. It also helps to cool the pump if there is always a flow.
The easiest way to do this is machine out a shouldered bore inside a spare carb hose tail. After rummaging in my shed I found some old bits of carb and unscrewed a hose tail. This was lightly bored out on my lathe and from a scrap bit of brass I turned an insert with 1mm bleed hole. It’s always important to turn a chamfer/cone on the end facing against the fuel flow. This helps if there are any dirt or particles in the fuel system. The hole is less likely to block as the dirt/debris tends to head down the chamfer/cone to the sides of the pipe and keep the hole clear.

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Finally I assembled the parts of the throttle linkage I d made this week after cleaning all the fold press machine marks out to give a brushed stainless finish. :)
The freshly gold BZP parts were added. (The return safety spring has the tension off in the picture. When fitted it will be rotated 180 Degrees, and the allen key is just holding in the throttle cable clamp temporarily for the photo). The remaining parts of the FI linkage are sitting by the side having been freshly plated with the rest. These will be bagged up and put with the other FI parts I’m slowly repairing/replacing.

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Tomorrow I plan on making the throttle rods and fitting it all onto the car. :)
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Darren C
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Re: Restoring my first 914

Post by Darren C »

This morning I had a lie in until 6am. I went and picked my son up and we spent a good 2 hours out driving in the Traveller. As the weather was blustery with constant drizzle all day, I let him get away without flatting and polishing a body panel after we’d finished. :wink: After a fry up brunch I dropped him home and started on the 914.

I had a good day fitting parts to the car and making a few adjustments to get this just right. :)

As I’d said earlier, Carbs were fitted from my shed stock way back in February to get the engine running for the first time in several years so that I could find out just exactly what I’d purchased blind. The paint shop had also said to me that they’d only take the car in for paint if it drove, so carbs were a quick no cost solution for me as I have numerous old & new sets in my shed from my VW days.
Here’s an OLD PICTURE from February, showing the “replica” Chinese Webers :roll: and an old Empi throttle linkage I used to see if the engine would run.

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I temporarily fitted rubber fuel hoses and used rivi-nuts in the factory holes to secure the fuel hose to the bulkhead. Again this picture is from February.

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Moving on to today I fitted the stainless steel fuel pipe manifold using the same rivi-nut fixing points for a neat out of the way installation.

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Next I fitted my home made throttle linkage. Far, far better than the mass produced Empi linkage I’d had on the car earlier, that is crude at best and not throttle cable friendly in a 914. This was the main reason for making a much better linkage that works well with the 914 throttle cable.
All those cornflake box templates, measuring & measuring again paid off.

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Perfect fit. :) :) :)
Next I made two 5mm diameter stainless throttle rods, LH thread one end RH thread the other, then fitted lock nuts and ball joints.
I then swapped out my old replica Webers for a genuine set of carbs and replaced the mains and idle jets to better suit a 2.0 litre. The floats were set and with new gaskets and home made stainless studs in the manifolds, they were fitted to the car.
This afternoon with a fire extinguisher at hand I ran up the engine and tuned the carbs with the linkages off before setting carefully the rod lengths (of the new stainless linkages I’d made this morning) and fitted them between carbs and main assembly.
With the 914 throttle cable fitted and adjusted it all worked a treat and looks pretty neat too!

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Just need to hunt down some tiny metal tubing this week to make a nice twin vacuum tube between carbs and dizzy. :)
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