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914World.com _ 914World Garage _ Fresh air box install video
Posted by: cuddy_k Dec 9 2018, 10:28 PM
Hi Guys,
Had a great time with @http://www.914world.com/bbs2/index.php?showuser=16669 , @http://www.914world.com/bbs2/index.php?showuser=6794 , @http://www.914world.com/bbs2/index.php?showuser=1351 and @secondwind working on @http://www.914world.com/bbs2/index.php?showuser=20991 's car yesterday and shot this video while we refurbed and installed his fresh air box. My hands still hurt, but hopefully this video helps the greater good.
Shout out as always to @http://www.914world.com/bbs2/index.php?showuser=3348 and @http://www.914world.com/bbs2/index.php?showuser=18454
Enjoy...
https://www.youtube.com/watch?v=Uhs6pedBOXM
Posted by: 914_7T3 Dec 9 2018, 11:27 PM
@http://www.914world.com/bbs2/index.php?showuser=18749 Video came out great and glad that this can be referenced for other owners going forward. Also pleased to see that the audio portion was edited so as to have a PG-13 version and not the rated R version as shot in real time.
Posted by: cuddy_k Dec 9 2018, 11:30 PM
If you listen closely, there are still a few "that's what she said"'s in there...
Posted by: raynekat Dec 10 2018, 12:41 AM
And "now" it's time to attach the cables?
You better have the one that goes on the back of the fresh air box already on the box before putting the box in....or God help you.
Virtually impossible to install the cable on the back of the box after it's in the car.
Otherwise, great video.
I liked the clamp idea; I'll use that next time.
On my install, I needed to sand down the outer circumference of the plastic screen from 914 Rubber as it was too big to fit with the gasket onto the box.
Posted by: porschetub Dec 10 2018, 01:04 AM
Yep not easy,would think a new seal would make it even harder 
,I cut blocks of wood to hold it up before doing the bolts up.
I did swear a bit but got there.
Posted by: cuddy_k Dec 10 2018, 01:25 AM
And "now" it's time to attach the cables?
You better have the one that goes on the back of the fresh air box already on the box before putting the box in....or God help you.
Virtually impossible to install the cable on the back of the box after it's in the car.
Otherwise, great video.
I liked the clamp idea; I'll use that next time.
On my install, I needed to sand down the outer circumference of the plastic screen from 914 Rubber as it was too big to fit with the gasket onto the box.
Yeah, the one on the bottom is a bitch. I find it more impossible to get the box installed with that short cable already clamped on the bottom, so I put it on after. I guess it's a pick your poison thing. It's not too terrible to install the bottom cable in-place. The cable through the screw part is pretty easy. It's the clamp around the sheath that's the bear. But with a long enough needle nose pliers, it can be done. That's what I did yesterday. Three times, actually...as the first time I hooked up the wrong cable and the second time the sheath fell out of the groove. Ugh.
Posted by: euro911 Dec 10 2018, 01:44 AM
Hell, I would have told my wife to wake me up early so I could have attended the event had I known Joe Walsh was going to be there 
Great video, Ian. It's the first time I've seen how the F/A box gets reinstalled. Good to know those tips, as I'll need to eventually do this on my car too.
EDIT: I checked out some of your other videos (control arm bushings, turbo tie rods & sway bar videos) - all top notch. Thanks for making & posting them.
.
Posted by: Porschef Dec 10 2018, 05:41 AM
Will there be a cable attaching video? Cuz that'll be the expletive loaded one... 
Nice job Ian 
Posted by: jim_hoyland Dec 10 2018, 07:18 AM
Thanks you ! Great How-T0 video; gotta see the cable attachment procedure....
Please move to Classics........
Posted by: DRPHIL914 Dec 10 2018, 08:51 AM
I agree with previous post about the clamp, this is a "golden nugget"* put an asterk on that one. I did this a couple months back getting car ready for Okteenerfest and almost just left the box out because the new seal was to tight, it took 2 of us and yes I had the cable on mine before so I wouldn't have to mess with it after but between the seal and the cable its not easy for sure. In the end we got it into place and its a nice snug fit so no leaks! Looking great, now get that motor in and drive it!
Posted by: Mikey914 Dec 10 2018, 11:24 AM
Great video. I've had many folks ask how to install the box. As you as see it's a bugger, but the rubber bands were an addition that I had not thought of.
NICE WORK
Posted by: cuddy_k Dec 10 2018, 03:12 PM
Thanks guys. I took some stills when I was installing the fan control cable and will try to make a video on that soon...
Posted by: rstover Dec 10 2018, 06:27 PM
I always appreciate postings on tips and tricks. I recently installed the air box and all the cables and ect. The first time I tried it never works, but gets better with each additional attempt. I ended up with this order on air box.
I separated the fan and air box.
1. Attached cable to fan housing.
2. Lay the fan flat a little forward.
3. Install box.
4. Connect the fan housing to the air box.
The most difficult part was getting the bolts started attaching the fan to air box after the air box was installed. This became much easier when I got some longer bolts 5mm bolts.
It would also been easier if the gasket between the fan housing air box was made of a material that would allow the fan housing to slide a little easier when trying to get the holes lined up.
Posted by: euro911 Dec 10 2018, 07:06 PM
I just added the air box gaskets to my existing 914 Rubber order, but had to go look at my '71 because apparently the plastic grilles didn't start showing up on the cars until the 1973 YM 
Yep, verified, no grille on the car 
Will the grilles fit the early cars? ... if so, I'll need to grab one somewhere ![popcorn[1].gif](style_emoticons/default/popcorn[1].gif)
Posted by: cuddy_k Dec 10 2018, 07:57 PM
@http://www.914world.com/bbs2/index.php?showuser=13785 Interesting idea to separate the box. I wonder if that's how the factory did it? I swear, some of this stuff is like trying to figure out how the Egyptians built the pyramids.
One way to make your approach even easier would be to substitute the fan assembly bolts with threaded studs. then all you'd have to do is put the fan on and spin some nuts down. Not concours, but kudos to any judges who can get their eyeballs under the air box 
Posted by: rstover Dec 10 2018, 08:20 PM
@http://www.914world.com/bbs2/index.php?showuser=13785 Interesting idea to separate the box. I wonder if that's how the factory did it? I swear, some of this stuff is like trying to figure out how the Egyptians built the pyramids.
One way to make your approach even easier would be to substitute the fan assembly bolts with threaded studs. then all you'd have to do is put the fan on and spin some nuts down. Not concours, but good luck getting a judges eyeballs under the air box
If I had not been fighting the foam gasket and had longer bolts I think it would have been fairly easy. If I was doing it again I would make my own gasket out of cork i think. I believe it acts more of a spacer than a gasket anyway.
Posted by: rstover Dec 10 2018, 08:46 PM
Don't want to hijack thread, but here is a pic. No doubt that figuring out the order of things is a large part of battle.
Posted by: Mikey914 Dec 10 2018, 09:14 PM
@http://www.914world.com/bbs2/index.php?showuser=13785 Interesting idea to separate the box. I wonder if that's how the factory did it? I swear, some of this stuff is like trying to figure out how the Egyptians built the pyramids.
One way to make your approach even easier would be to substitute the fan assembly bolts with threaded studs. then all you'd have to do is put the fan on and spin some nuts down. Not concours, but good luck getting a judges eyeballs under the air box
If I had not been fighting the foam gasket and had longer bolts I think it would have been fairly easy. If I was doing it again I would make my own gasket out of cork i think. I believe it acts more of a spacer than a gasket anyway.
Cork would be harder and yes you would definitely need longer bolts. The closed cell foam is what factory used and mine is 1/16" thicker
Posted by: 914_7T3 Dec 10 2018, 09:34 PM
I just added the air box gaskets to my existing 914 Rubber order, but had to go look at my '71 because apparently the plastic grilles didn't start showing up on the cars until the 1973 YM
Yep, verified, no grille on the car
Will the grilles fit the early cars? ... if so, I'll need to grab one somewhere
@http://www.914world.com/bbs2/index.php?showuser=7300 I have an extra 914 Rubber one as I used an OEM one that I picked up from @http://www.914world.com/bbs2/index.php?showuser=453
PM me if interested!
Posted by: 914_7T3 Dec 10 2018, 09:43 PM
And "now" it's time to attach the cables?
You better have the one that goes on the back of the fresh air box already on the box before putting the box in....or God help you.
Virtually impossible to install the cable on the back of the box after it's in the car.
Otherwise, great video.
I liked the clamp idea; I'll use that next time.
On my install, I needed to sand down the outer circumference of the plastic screen from 914 Rubber as it was too big to fit with the gasket onto the box.
Yeah, the one on the bottom is a bitch. I find it more impossible to get the box installed with that short cable already clamped on the bottom, so I put it on after. I guess it's a pick your poison thing. It's not too terrible to install the bottom cable in-place. The cable through the screw part is pretty easy. It's the clamp around the sheath that's the bear. But with a long enough needle nose pliers, it can be done. That's what I did yesterday. Three times, actually...as the first time I hooked up the wrong cable and the second time the sheath fell out of the groove. Ugh.
Also helpful to have extra clamps on hand as they tend to break. Luckily we had a parts car on site where we could secure extras to complete the installation.
Posted by: 914werke Dec 10 2018, 10:16 PM
Yep, verified, no grille on the car Will the grilles fit the early cars? ... if so, I'll need to grab one somewhere @http://www.914world.com/bbs2/index.php?showuser=7300 I have an extra 914 Rubber one as I used an OEM one that I picked up from @http://www.914world.com/bbs2/index.php?showuser=453
cheap insurance for any early car to keep that fresh air fan operating. 
Posted by: cuddy_k Dec 11 2018, 01:02 PM
[/quote]
Also helpful to have extra clamps on hand as they tend to break. Luckily we had a parts car on site where we could secure extras to complete the installation.
[/quote]
Ummm.. yeah. If I hadn't installed the wrong cable the first time, I prolly wouldn't have broken the clip taking it off 
Posted by: bbrock Dec 11 2018, 03:26 PM
Also helpful to have extra clamps on hand as they tend to break. Luckily we had a parts car on site where we could secure extras to complete the installation.
Ummm.. yeah. If I hadn't installed the wrong cable the first time, I prolly wouldn't have broken the clip taking it off
Is there a good source for those clamps other than parts car?
Posted by: bbrock Dec 11 2018, 05:44 PM
Is there a good source for those clamps other than parts car?
Thanks to @http://www.914world.com/bbs2/index.php?showuser=13785 , I was able to track down a part# (901-571-919-00). Still available through Porsche... at Porsche a price considering what they are. Thought I'd post it in case anyone else is looking. BTW, I'm told these might not arrive with the yellow chromate finish.
Posted by: Big Len Dec 11 2018, 06:15 PM
Where's the "Like" button?
Good job.
Posted by: euro911 Dec 11 2018, 08:45 PM
... whereas Pelican wants $5.75/ea., but they're only a few miles away - and I need to order some other parts from them anyway, so ... Posted by: 76-914 Dec 11 2018, 09:08 PM
That's a neat trick, Ian. Good job and great video!
Posted by: ThinAir Dec 12 2018, 11:16 PM
Really appreciate this. I'll add my vote for the cable attachment video. I'm sure that I didn't get mine right when I reassembled my car after repaint. Getting it right is on my todo list.
Posted by: barefoot Dec 13 2018, 09:04 AM
I just did mine, getting the fresh air box in was not too hard. I did loosen the 2 braces and also loosened the wiper assembly as it was interfering with getting the box in all the way.
The Really painful part was re-attaching the control cable at the back side. There was NO way to pre-attach the cable before positioning the box as it isn't long enough without dis-connecting it from the dash control levers, and that would have been even more painful.
Getting the cable into the lever isn't too bad but but getting the clip snapped back on drove me crazy. I finally got it snapped in but was about to go the the hardware store to buy some long heavy duty needle nose pliers.
Attaching the electrical cable was fairly easy.
Good luck out there
Barefoot
Posted by: cuddy_k Dec 13 2018, 09:47 AM
I just did mine, getting the fresh air box in was not too hard. I did loosen the 2 braces and also loosened the wiper assembly as it was interfering with getting the box in all the way.
The Really painful part was re-attaching the control cable at the back side. There was NO way to pre-attach the cable before positioning the box as it isn't long enough without dis-connecting it from the dash control levers, and that would have been even more painful.
Getting the cable into the lever isn't too bad but but getting the clip snapped back on drove me crazy. I finally got it snapped in but was about to go the the hardware store to buy some long heavy duty needle nose pliers.
Attaching the electrical cable was fairly easy.
Good luck out there
Barefoot
Yep, that's pretty much the deal. Getting the clip on the bottom cable involves aligning it perfectly straight with the bracket (blindly by feel) and using enough force to bend the clip around the sheath and lock it in. Long needle nose pliers are the tool of choice...but it's difficult to find a good angle for them to grab just the top of the clip. You may need to move the lever / cable a bit to clear the hardware which moves the vanes. Also...make very sure you're attaching the fan control cable (the top slider on the control inside the car)...and that the sheath is sandwiched between the clip and the bracket so you don't have to go through that pain more than once. Ask me how I know...
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