964 C2 - Rolling Resto

[rhd racer]

You know me James - if it is possible to over engineer something then I’m away….

I have been doing that after the last cock up, which is ok but not ideal. also a PITA if by the side of the road


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[yoda]

Air jacks?

[rhd racer]

Ha ha - it probably spends too much time in the air, but not that much!


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[rhd racer]

When is an eBay purchase not quite as good as you thought? When you take off the heat shield and find a dirty great crack in it



Still I persevered and marked the flange before cutting it off- mostly with a 1mm cutting disc being careful not to damage the pipe I need to weld to, then a grinder to finish off




Them
Putting it in the vice I could use the pencil file to grind out the old welds on the inside


I then welded it up and painted most of it save the area where the flange goes, which is yet to arrive

The old cat is prob a 100 cell, it has the gauze inside but you can see daylight through it so doubt it does anything!



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[hot66]

Got my old one welded up but only use it when I ‘need ‘ to … but just bought a new 200cell from Germany for not too bad money… well it will be depending on what I get stung for import duty and vat etc .

[rhd racer]

Let me know how you get on James - these have been repaired before so am not sure how good they are going to be


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[hot66]

Current cat delete sounds great , but you can smell it . Nice pops on the 2nd - 3rd full throttle up changes though.

[rhd racer]

I suspect my lack of anything meaningful in there was contributing to why the G pipe was so loud! I have a sports rear silencer so I suspect in combination it was like putting a cup and G pipe together. I have a new cup pipe that I have never fitted for that reason!

I have been working through the list and had a good day on the car yesterday, which turned out to be a school day…..

I very nearly have one of the few ‘dry’ 964s around - but not quite. Now I have stopped the oil dropping out the bottom from above, I had a good look and found a weep from the main line from the tank, which was throwing its voice and running to the lowest point on the block, creating a wider footprint of oil than it really deserved








Whilst under there I noticed that an exhaust fixing had made a bid for freedom too…



First job was to drop the oil as it is 2 years old and due a change. Only about 2000 miles on 100 quid of oil is not great value but I will try harder. As expected it was clean as a whistle with only a tiny mist of deposits on the sump plug



Whilst it was draining, I finally got round to fitting the rubber seal that caught fire in the heat exchanger last year - turns out the rubber was seated correctly (a blind connection) which I sorted



And I found this in there - no idea where it came from…



Then fitted the new seal and reconnected




Next up heat exchanger removal - easy on a new engine with new studs and nuts surely?


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[rhd racer]

Experience has taught me to always do the most difficult buts first, whilst they are not taking the load. This one at the front of the engine (rear of the car) shouted trouble from the outset. I went through my toolbox in the garage, house and each car looking for spanners with different profiles that would reach - not one.




The second pic illustrates that the spanner won’t even get near the nut. I looked at sockets with wobble extension bars and wobble couplers but no good. I could get a socket on it but then could not connect anything to it.

I had worked out that 1/4” was going to be the only way because the physical size got closest, and worked out that I might just get in it if I cut a socket in half - and so it was!



With a wobble extension I could just get on it. The others were not exactly easy, but having 29 different spanner / socket combinations worked it out. The 4 bolts at the rear to the crossover section were rusty because they get all the dirt but came out ok after a soak.

I then gave it a good degrease along with the rest of the engine



I know had access to the case insert and pipe- one is 30mm the other 36mm. In usual style the inset coupling came undone and not the elbow. It also wasn’t very tight, but looked to be leaking at 3 points. I couldn’t split them on situ so had to wind it all out, putting pressure on the elbow which subsequently broke in my hand, the end falling in the oil pan.




Being Bank Holiday I set about ordering a new elbow - £125 for a de match item or £170 for OE but not in stock. So I went for the cheaper one and because it looked like the rubber elbow it connects to also looked wet I got one of those too. And then to make up the postage ordered new wiper arms and blades, both of which are looking tired. £250 lighter than I was 10 minutes earlier I went to fish the bits out of the oil.


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[rhd racer]

Hilariously this revealed the the elbow is actually a 3 piece affair, and goes back together….Lordy Lordy




.


After smacking myself about a bit in the garage I reasoned that I would be fairly miffed if I put it all together as was and it was still leaking. The cost of the oil change alone made it worthwhile.

Looking at the washer with the union it looks totally the wrong size and possibly part of the problem. I have ordered a box of dowty washers and will put sole oil thread jointing compound on it when I refit it.



I got all the new hardware together for the refit and am just waiting for parts now to refit it all. I have moved onto wet and dry on the bumper as I have the shape pretty well sorted. I am under no illusions this is going to take forever to get it spot on so am just picking it off bit by bit as I walk past it.




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