DDK - Die Deutschen Klassiker

Thanks again for the kind words. I hope the thread helps Chief.
Canarydelia (not sure about the Norwich connection in Brum?) funny you should say about you tube…..I have done a few how to’s for other car clubs in the past under the guise of “one take wonder productions”; worked my way through the terrestrial TV channels, satellite TV and ended up with Universal Studio’s & MGM, suffice to say at any given time I’m on TV is some country or another, but they’re stories for another day.
Milhouse, thanks for the link, but today I did this….



It’s out in one piece

The work late into the evening last night cutting out as much sealant with Stanley blades paid off. The guy turned up this morning with his cutting wire and it was out in about 30 seconds. To be fair there was only about 15% of bonding left around the trim clips that I couldn’t get to with the knife, so it was a case of dot to dot with the wire and job done. In addition there was a good 30% that had come unstuck itself already over the years which helped no end.
Not to scare monger anyone who hasn’t checked theirs but I was very pleased to get the screen out as without a doubt it would have leaked like a sieve if I’d left it untouched.
Timed with an early lunch it was 30 seconds well spent.
Getting back to work earlier than anticipated I did a quick search for more parts but got very side-tracked by logging on DDK. Fatal…you simply can’t restrict yourself to only 5 minutes on here, so much good stuff and deeds to be done.
Anyway this evening I returned to the car and started to clean up the aperture
The majority of the surround was in perfect condition with zero rust (even in the corners) which was very welcome. With the glass out I could properly remove the surround trim clips. I have a new set with the new surround, but saved the old ones non the less. (just in case I break a new one)
Nearly all the trim clip holes were rust free too.



With the exception of 4 trim clip holes in the centre of the bottom of the aperture that had some small evidence of bubbling around them.
Two hours later I’d stripped the bottom of the aperture down to bare metal and sanded down a tiny amount of rusting about the size of a little fingernail until it was all gone.
A final coat of encapsulating primer and it was getting dark. A quick deserved cuppa was had while the primer dried before the cover went back on.



Yep I know.....the dash replacement is next on my list
Finally I loaded the windscreen carefully into my car and took it home for safe storage.
Driving Miss Daisy all the way home with the precious cargo.

Last night it was getting dark when I got home so when I unloaded the windscreen and a few bits and bobs I just placed them inside the front of the garage. This morning before work I sorted out some old underlay and made a nice nest in the rear of the garage to keep the screen safe while the car gets painted.
Over lunch I read up on how to remove the rear window and ordered some 3M Butyl 1/4" tape to put the glass back in with.
After work I went up to the car and started to dismantle the interior to get at the rear window. Everything came out as planned and the reverse of the glass was all revealed. While working on the engine bay repaint I knew it was rattling around but I wasn’t prepared for how lose it was.
Reaching in from outside I gently tried the window and it literally fell out into my hands!
I lifted it out and placed it to the side to take stock.
The old butyl tape was completely sand logged, it must of worked its way into the gap between glass and seal and stuck in there. Fortunately it just gently peeled out leaving a nice clean window aperture, no rust to be found.
Unfortunately everything was covered in sand behind the panel (no surprise) the seat belt reels were choked full of sand, so they had to come out for strip and clean. Most of the pieces of vinyl that were stuck here and there to cover gaps around the rear padded bulkhead had curled up and were extremely crispy, so they all came off too.
Thinking ahead and to really get the sand out I decided to take off both sill carpets. Drivers seat was still out from the glass removal so I took out the runners and handbrake to free the carpet. Passenger side was much easier, the seat stayed and just the seatbelt bolt and a screw in the front speaker cover held it in.
Lifting the carpets out poured more sand everywhere.
I then gently removed the last of the roll bar vinyl off the top centre section, loosening off the latches to free it from behind them.
After bagging up and labelling all the fixings I loaded them up to take home and returned to off load at home as it got dark.
I did manage to take a picture before the sun set of today’s escapades..

Today was a bit Groundhog day. This morning I sorted out the glass and interior bits out into safe storage that I brought home last night and at lunch I searched out a few more parts.
The clear cover is missing from the fuse box and I found one on-line for a few quid so ordered it up.
The two buffer stops I’ve been searching for that fit inside the engine lid hinge were finally tracked down. Part number 914 559 253 10 is no longer available, but having searched a bit deeper it seems like the part number has changed to 901 423 528 00
These are still available, so I ordered some this lunchtime. I also called in at the letting agents and checked out what was happening with the garage that they are taking rent for that I can't use because the door is broken. The bad news is that they aren't allocating any funds to low priority defects but gave me numbers of two other garages in the block that are empty to see if they are serviceable. Call me old fashioned but shouldn't they be doing that, then contacting me? It just seems that with everything in life you cannot rely upon anyone these days, if you want something done you've got to do it yourself. I'll post an update on the garages when I've had time to check them out.
This evening after work I visited the car and made a fitted cover from some thick polythene sheet and some old U channel edge trim to cover the engine between rear window and boot to help stop dust/dirt ingress while the car is at the painters. I’d had some sheet over it for a while now, but cut it all to size tonight instead of the sticky duct tape it's had on for a few weeks.
I then spent another 2 hours sanding down the boot floor to feather the edges of the paint and scratches ready for spraying before running out of light again.

Hi Darren, I also need a fuse box cover - can you tell me where you got your's from? Thanks,

The Fuse cover was from Pelican new at $29 USD, I had a few other bits and bobs so put it in the same delivery to save postage costs. If you just wanted a fuse cover I’m sure if you email them and get it in a jiffy bag & snail mail (if you’re in no hurry) the postage will only be a few quid as it’s not very heavy.

I had a good day working on the car today. As its booked in on Monday at the paintshop I needed to get the brake system closed up, so ended up fitting the new callipers over the old discs. Not what I initially wanted to do, but since my second set are still in transit I had no option. Anyway I got it all buttoned up and bled. First time in many years that it’s held fluid.
During bleeding I noticed excessive pedal free play. The result of a pedal assembly rebuild and a new master cylinder. I adjusted the rod to give a nice 1mm as per the Haynes data and locked it off with the lock nut, job done.
Next I carried on sanding in the boot floor for a few hours before finally getting a coat of primer on it.
Afterwards I put a good amount of seam sealer over the rear of the side marker blank plates to fully seal them.
Out with the vacuum cleaner and the interior and bulkhead was cleared of more sand from when the rear window came out. I gave everything a good wipe down with a damp cloth and cleaned up the sound deadening pads.
Then on to the rear window surround. I’d peeled off what was left of the butyl tape the other day but on the outside an attempt had been made to seal the glass with silicone sealer, this took a while to pick and scrape off, but it was all removed in the end.
Under the roll bar outside there are 3 blank plugs each side. Mine had been sprayed over during the poor respray in the past, so I had to chip the paint off them to get them out. I certainly will be making sure it gets painted properly this time around and after getting the plugs out I dropped them in a small pot of cellulose thinners for 10 minutes until the paint had crinkled and fell off. Fortunately all 6 are salvageable and will go back in plain black plastic coloured.
Finally I cut up another piece of the polythene sheet and blanked off the fuel tank area under the windscreen held in place with some old off cuts of U trim. The paint around the fuel tank is excellent so I don’t intend to get this re-sprayed, just the boot itself, as far back as, and including the bulkhead. Apart from the engine bay, fuel tank area, underside and interior where it’s fine everything else is getting fresh paint.
Tomorrow I need to do a few more little jobs to do before its loaded up on the transporter.
Finally I returned home this evening to find my "Certificate of Authenticity" from Porsche arrived in the post

Today was an early start to get all the final jobs sorted out before tomorrows trip to the Paintshop.
Whilst working on the car it was most practical to have all bonnet, boot and door latches on the car, but for paint they needed to be removed.
I started with the boot lock and catch, then the pin on the boot lid followed by the two rubber adjustment stops on each corner. Fortunately the boot stays down by itself so nothing needed there to hold it.
Next I moved on to the front Bonnet, removing the catch and nylon cable sheath. I coiled the wire up and cable tied it, then tucked it beside the petrol tank.
Then came my first hurdle today the latch on the bonnet itself. I took the left bolt out then noticed the right bolt was loose. I put a socket on it but it was solid, yet all the washers and catch were loose. It was as if the bolt was too long and bottomed out?
It was solid so I turned the ratchet and SNAP, the head sheared off. On closer inspection the PO had put a ¼ UNC bolt into an M6 hole and wrenched it as tight as it would go! Now I had to carefully drill out the sheared bolt. Working up in drill sizes I got to 4.5mm and the old UNC bolt (or what was left of it) freed off and came out. I tidied up the thread with an M6 tap but it was completely stripped.
The catch is safety critical so I had to re-tap it to M7 to get a good thread. Just need to order an M7 bolt for it to go back on. (didn’t want to go to M8 as it would look out of place and leave less meat in the backplate. The M7 head will be at a glance the same size as the M6 head, so it will look ok)
I then took off the check straps and interior light switches (taping up and pulling the cables back into the car).
After a trip to Halfords to buy a pack of two 450mm bungy straps, I took off the door lock mechanisms and striker plates. The bungy straps linked together hold the doors firmly shut when stretched behind the seats. Easy to take off for painting and a simple practical solution to aid the car moving around.
Next I started to strip down the targa roof to just a bare GRP panel. Not only did I remove the seals and trim, I stripped off the old headliner material too. It will be painted both sides for a good job.
Finally we loaded the car onto the transporter ready for a 6:30am set off to the paintshop tomorrow morning before work.





Again this afternoon when I got home (first time in a while it was light) I put all the locks and stuff into my shed ready for refurbishment. Walking back past the side gate I noticed a parcel. Must have arrived yesterday but I’d not noticed in the dark.
Opened it up and found my very nice NOS genuine Porsche Bumper Grilles



David, the new parts met with my approval so as promised if you pm me your address I’ll send you my old ones for your conversion.
After a whole weekend of 914 work there was just enough time for me to get out another classic and drive over for the last hour of a car show in Portsmouth this afternoon. All American cars (but no 914’s to be seen).
When I got back this evening I cleaned the other car and my Volvo, then put the door locks into a white spirit soak to loosen all the sand and old grease off them, while I mowed the lawns again.

Furiously scribbles yet more notes in little book of lots to do

Loving this thread, thanks for posting in such detail.
I truly cannot believe how few people are into these lovely little cars. I think their day will come, soon!

Thanks again for the encouragement Chief

This morning I awoke to the dawn chorus of songbirds at 5:15am, today was the day the 914 takes a trip to the paintshop. 4 months of continuous preparation have lead to today.
Before breakfast I loaded up parts into my daily driver that I’d taken off that needed paint (including the engine lid etc) and drove down to the paintshop to await the transporter at 6:45 to help unload.
Like clockwork we got the car off in glorious sunshine and the transporter left while I waited until 7am for the paintshop to open.
Stuart, the owner turned up on time and we spend a good 15 minutes going around the car discussing my requirements. He’d seen it a few weeks ago when it was still together so now had a good look at the detail. We checked his old original VW paint colour chits (that’s the beauty of going to a classic VW specialist, they have a passion for the car plus all the original VW paintshop information to hand). I unloaded the parts out of my boot, handed over the keys and left for work.
Stuart reckons 4 weeks, I bet him it would be 6!
There’s no real deadline I’d rather it took a little longer and was right, after all I’m a fussy bugger when it comes to detail.
Today at lunchtime I paid a customs charge on my Brake discs and they should be here tomorrow. Typical really, as I’d hoped to get them on at the weekend, but never mind, they’ll go on when the car gets back and it’ll give me plenty of time to paint up the hub and edges.
Over the weekend when taking the targa top to pieces I’d noticed lots of screw head cover plugs missing so spent the lunchbreak searching the PET and internet for the missing plugs.
Tonight when I got home, I spent a good couple of hours sorting out the door locks that were full of sand. Since the car arriving in the UK the handles were very, very stiff to operate, almost to the point that I was scared of breaking them. No wonder when found them jammed up with sand.



Last night I put them in a white spirit soak to dissolve all the old grease and loosen the sand. After a couple of hours with an old tooth brush I’d got them back from the dead, no more gritty grinding movement here.





Just before it started to get dark I brushed a very light coat of waxoil on the mechanism (avoiding the pivots which will be greased with waterproof marine grease) just to keep them looking like new in the British weather.
Next I put the check strap mechanism and the bonnet lock in soak, for déjà vu tomorrow night.
Retiring inside I opened another very large parcel that arrived this afternoon from 914rubber.
All my 914 rubber Christmases arrived at once; cant wait to start putting it all back together with all this nice supple new rubber.



How many seals can you identify ? (just kidding)

Finally I boxed up my old bumper grilles for David to post off tomorrow.

This morning I got up at the crack of dawn again and changed a starter motor on one of my other cars before leaving for work. I’d been meaning to do it for a while now and with the 914 work, it had been placed on the back burner. This weekend I need to move it to get another car out so it had to be done.

Over lunchtime I searched down a few more bits and bobs and visited the Post Office to send David my old bumper grilles

Tonight when I got home I started on the door check straps that had been in soak overnight. As I’d mentioned earlier the drivers door creaked when opening and just didn’t feel smooth. All was revealed when I dismantled the door and found half a roller in the bottom.
The other half was still stuck in the sand logged mechanism You can just see the half around the pin in the picture



The passenger door was much smoother (less use maybe) but not quite right either.

I always find that any man-machine interface needs to be a pleasurable one. As a creature we evolved to be tactile and any interaction with a car needs to give us the right signals. From flaky razor sharp chrome on door handles, rough sandpaper dry paint jobs where the gun couldn’t get in, to play in a steering rack they give off repulsive signals that completely destroy a pleasurable experience. It’s the little details that make a big difference when you restore a car. I remember once meeting some bird in a nightclub in my youth and going back to hers and running my hands up her blouse to remove a bra and finding what can only be described as Artex under her armpits. Deodorant on top of deodorant (several week’s worth) put me right off It’s the same thing as I’m talking about with getting the tactile things right on the car.

In my quest to sort out the check straps I found a nice little kit while on the 914rubber website. “914 Door stay roller replacements Rollers Part No 914DSRR $19.99” Contains two nylon & two aluminium rollers.
They came yesterday in my big parcel, so I spent a couple of hours stripping down and cleaning the passenger check strap assembly this evening. The “didn’t feel right” ended up being a very big flat spot on the nylon roller. You can just see it in the photo below.



New roller kit shown bottom right in picture above.

Again it got dark too quickly so I finished off with another light coat of waxoil on all the parts ready for assembly tomorrow when I’ve cleaned up the drivers side mechanism.
It’s a real simple fix and makes a big difference.
Unlike my previous check strap restoration on another car where I had to make the parts as good useable secondhand ones were Uber rare and unobtainium.

http://www.tomyang.net/cars/phpBB3/view ... rap#p32931

Thanks Darren, donation made

Keep the updates coming Darren, I look forward to hearing/seeing what you've been up to each day!

Funnily enough I was browsing around the 914rubber site the other day and was looking at that door stay roller kit amongst other goodies!

Also just read that whole thread on the ferrari forum - is there any end to your talents - very impressive.

Regards

Joining the club Darren. Just got back from picking mine up. Your thread will be invaluable in the coming months. Keep posting please!

My wife is usually a lot happier I'm amazed I'm still actually married!!

Oooooooo Very nice Chief,

Looks like the car I looked at on sale in California then bought by the Camper guy's in Banbury ??

I'm going to have to re think my new paint job now......too many Alaska Blue cars

Cheers David & Nathan

This morning I assembled the passenger check strap with new rollers and waterproof grease before work. I did have to tweak the main frame that holds the nylon roller. The gap between the frame was tight and binding the roller so it needed opening up a mm so that the roller spun freely.
Today at work it was meeting after meeting so I didn’t get chance for lunch today.
Getting home tonight I had two parcels waiting.
Two new RHD H4 headlights that I ordered from David Manners Group.
Part No LUB328LUCAS H/Lamp no pilot H4 Bulbs £34.66 inc VAT the pair
When I took the lights out the car the other week the plug that fits on the back of the lamp (holding 3 spade connections) just crumbled. California heat damage. I got a new pair with the lamps, just need to relocate the spade terminals into them.
The second parcel from Auto-Atlanta contained the rubber grommet/tube assemblies that the wiring to the sidelights and indicators pass through between bonnet tub and front wing.
After checking all parts over, they arrived without damage/defects I placed them into my storage shed to await rebuild.
I then stripped down and cleaned up the drivers check strap assembly. Not only was the nylon roller in pieces, the Aluminium one had two very large wear flats on it at 90 degrees to each other. The strap itself is made of aluminium too which did surprise me. They have a knurl (serrated ridged edge) where they run in the rollers, presumably to encourage them to rotate. It seems that if the rollers seize up the check strap acts like a file and wears them flat until (as with mine) it wears right through the nylon roller cutting it in half. It them runs on the steel pin and wears the aluminium check strap down on the edge which burrs it over along the edge so that it then sticks/jams inside the aluminium roller as its too wide with burrs to run freely.
Most people just put grease on their check straps. On the bits you see when you open the door.
This it seems is not enough for the 914 design, you’ve got to take it out the door to lubricate these rollers and make sure they turn freely for a long serviceable life.
So after cleaning up all the parts of the drivers assembly and filing down and smoothing off the burrs I gave them a light coat of waxoil and left them to dry until tomorrow morning like I did with the passenger one.
There was still enough time this evening to clean up the bonnet lock assembly that was soaking overnight, dry it out and coat with waxoil.
With the waterproof grease still open from this mornings assembly I next turned my attention to the recently cleaned door locks. Taking my time I worked more grease deep into all the pivots, latches and catches to get a nice smooth operation before finally calling it a night.

This is a great diary/thread.
Always good when a restoration is so active!

I've never used white spirits to soak and loosen and clean and then a spray of waxoil before, new technique on me, but looks to work really well from your examples.

You learn something every day.