Rebuiding Inside-out Options

[bkrantz]

I realize most rebuilds go from the inside to the outside, but I am struck by how straight and clean the outer panels, including paint, look on my 73 2.0. And all the nasty stuff is hidden underneath--which I know is also not unusual.

Any way, I bought the car knowing most of what it was: a 2.0 with all the sport and appearance group equipment, including 5 good Fuchs, and the original fuel injection. The original engine is confirmed by a COA. In contrast to the exterior the interior was mixed at best, with some funky carpet. And the front and rear trunks (and engine compartment, and interior) had been sprayed with black undercoating.

So after a month, I have the car stripped to a bare shell, except for suspension and steering. I measured everything I could, and the body is very square and on spec. I need to patch some local rust spots, and replace the rear floor. And then do some minor straightening: right headlight bucket, front edge of right front fender, rear panel, etc.

[bkrantz]

New fuzzy channel for the window guide.

[bkrantz]

Installed.

[bkrantz]

Now the fun part: trying to get the seal seated in the door.

[bkrantz]

After lots of struggle, I could not get the front end to seat properly.

[bkrantz]

And the outer part of the seal will not seat horizontal, with a bulge next to the retainer tab.

[bkrantz]

And worst of all, I split the outer seal above the slit I made for the tab.

I know others have done this by cutting the tab off the retainer, but I figure Porsche put that there for a reason. I will have to consider options.

[iankarr]

Definitely tricky business. Mark at 914rubber provided the best tip...wrap the triangle glass and channel with cellophane pack-wrap. It keeps everything together and stable while you muscle things in. I also needed to to trim things a bit to get everythng to seat properly. You may want to check that the glass isn't hitting the frame, keeping the seal from being far enough forward for it to fit in the channel.

[bkrantz]

Thanks, Ian. I tried a few times with different approaches, but will never get the bottom edge to sit evenly because of the tab on the retaining bracket. I have ordered the factory part, which should have a groove for the tab.

[raynekat]

Bob....I must have tried installing this triangle window 20 times. Couldn't get the 914Rubber seal to work.
Eventually went back to the factory seal and finally had a satisfactory result.
Getting the door seals to work correctly on the A, B pillars and targa top is definitely a challenge.
Takes a lot of patience and cyphering. (IMG:style_emoticons/default/wink.gif)

Hopefully you won't have fitment issues when you go about mounting the door on the car.
I had my doors installed, such that I could check fitment against the A pillar.
There is definitely a lot of tweaking that took place in my case.

[bkrantz]

You are right, Doug. If there is any general category of jobs, anything that involves rubber seems to be most challenging. And especially where multiple parts have to align properly. Best to do those on positive karma days. And as you will see, I have decided to try the doors-on method.

[bkrantz]

Yup, doors (at least right door), going on the car. How about some new door stop retaining pins? The ones from 914Rubber measure .01 inch larger diameter than stock. To make them fit, I had to drill the stay arm, and ream out the paint from the holes in the tabs on the door jamb.

[bkrantz]

Tidy fit with no slop.

[bkrantz]

Quick adjustment of hinge positions and latch looks pretty good. Once I get the new vent window seals I can try that again.

[bkrantz]

Meanwhile, back to the engine. Here is the new (used) alternator front seal, plus some more hardware.

[bkrantz]

The hardware furthers my quest to replace all the slotted fasteners on the engine with Allen heads. Note the big Philliips screws are not original but I used them when I first put the blower housing together.

[bkrantz]

I pulled all the sheet metal off the front, just so you can see the housing with Allen fasteners.

[bkrantz]

Alternator ring in place.

[bkrantz]

With all the sheet metal back in place, it was time for a new V-belt.

[bkrantz]

Just a bit of tension, and ready.

[TX914]

The hardware furthers my quest to replace all the slotted fasteners on the engine with Allen heads. Note the big Philliips screws are not original but I used them when I first put the blower housing together.

Funny story - Many years ago I replaced every slotted fastener on the sheet metal with Allen heads because I thought they were easier to work with and looked cool. The next time I had the car in the shop the mechanic replaced every one of them with the original slotted fasteners without even asking. I guess he did not agree with that mod. (IMG:style_emoticons/default/smile.gif) I think they were not tapered and were thus harder to thread.