Freitag, 29. April 2016

ARB (Anti Roll Bar) refreshed

A few days ago I assembled the freshly powder coated front ARB with this pile of Porsche rubbers and bits:

(Note, the new washer is plated in silver, as the "gold" cad plating is no longer allowed in Automotive, due to the hexavalent chromium which is harmful)

I didn't chose the poly bushings, I think the Porsche rubber is good enough - as Porsche used it in the first place - and on all my aircooled VW's the poly bushings squeak which annoys me everytime. Also (and surprisingly) the Porsche parts were really cheap! All 8 rubber bits together were under 50 €!

This is the result:

Next step is the refurb of the front struts...

Sonntag, 17. April 2016

Coolant tank

On a Porsche 944 the coolant tank is affixed in the left wheel well (example - not mine):
 (Picture found on

It exactly follows its contour. Problem is: Due to vibrations, the tank scratches off the paint, leaving some surface rust.

The tank from below:

I touched up the scratches with some white Hammerite: 

Some thin self adhesive felt pads in the right spots should prevent this to happen in the future: 

Samstag, 16. April 2016

Hood latch

When I removed the filthy hood latch:

I had to cut the release wire. Now, with the refurbed lach I had to fix this. I have a ton of  Bowden cables in my parts stash - but none like this:

 and I wasn't keen to pay Porsche money for a simple Bowden cable. So, I used an old brake pad pin and modified the release lever:

I attached the cable to the latch and riveted it back into place:

Freitag, 15. April 2016

Front brake calipers

Today I assembled the front calipers: New seals, rubber boots and bleeders:


Here are the new springs:

 New Brembo pads and Porsche mounting hardware are next for the front calipers: 

 ... and Textar pads + Porsche hardware for the rear calipers:

Also, the warning contacts will be replaced as well.

Donnerstag, 14. April 2016

Brake caliper refurb - Amazing results!

When I dismantled the brake calipers 3 weeks ago, they were in a sorry state:

So, I polished the pistons. re-assembled them into the cylinders and send the parts over to my fellow buddy Jens, the Master Blaster. All components were media blasted and cad-plated. I also send over some bolts and bits:

as well as some brackets for powder coating:

Especially for the brake bits I didn't expect much, they looked far gone - but:
Here are all those parts + new refurb kits from ATE:

Front calipers:
I cannot believe how nice the came back to live!

The pistons, freshly polished, without the cylinders:

and the rear calipers:

I already assembled the rear ones: All seals and the plastic sliders are replaced, new vent valves as well:

The only thing left to do is to align the pistons and assemble the pads and sensors!

During the weekend I will assemble the front calipers as well.

Usually, I like the silver-colored plating better, but as Porsche always used the yellow plating - this was the way to go:
Hood latch, ARB brackets and misc. parts look better than new again!
Thank you Jens for super service, once again!

The air filter brackets and hood latch are re-assembled already:

Dienstag, 12. April 2016

NLA !? - Not for Volkswagen Classic Parts !

Whenever you try to order a spare part and the answer is NLA - You are in trouble.
NLA = No Longer Available... I am collecting all parts required to overhaul the 4 brake calipers and the front guiding springs ( I know, this is almost unheared of, but some calipers do have a guiding spring) are NLA at Porsche. In fact the guy at the parts counter said to me: I am working since 38 years in Porsche and I have never seen or sold this part - the last price in the list was 10,38€ - but is listed as NLA! 
Luckily, in this case it is a common part between Porsche and VW, so I checked with Volkswagen Classic Parts. They still have these parts available and @ 2,73€ +tax each - the postage was higher than the price for the 2 springs, but the point is: I have them and I can rebuild the calipers soon!

Sonntag, 3. April 2016

Driver seat: fixed!

Yesterday I picked up the driver seat which needed some attention:
The back and seat bolsters were cracked:

Now it is repaired and looks so much better:

Both leatherette parts were replaced with an alomst perfect identical material!
The seams in the seat bolster we re-sewed as they were gone already.
Usually I like to do things on my own, but if a specialist is required, I am happy to pay him for a good job!
This is the guy in charge: