Orange 75 project, Clutch and Shifter setup Options

[my928s4]

Fantastic work so far! You sir are a hero. An inspiration to me to just get out and get on with it! I like your systematic way of tackling jobs a little bit at a time making sure to do it right without getting worn out and frustrated i.e. taking breaks to watch F1. Can't wait to get one started myself and plan on using your posts for reference. Thanks for the confidence. (IMG:style_emoticons/default/smilie_pokal.gif)

Kind words, thankyou, feedback from you and everyone else keeps me motivated also (IMG:style_emoticons/default/smile.gif)

Yes I find the need to take a break once in a while, keeps the sanity.

[my928s4]

So the goal of assembling the front suspension was squashed when I needed different struts and I find this week they are on backorder till the end of April (IMG:style_emoticons/default/sad.gif) I assembled what I could which is enough to balance the car on the trolley so I can ditch the spare wheels in the trunk.

Looks empty in here, needs a sway bar for sure!



It was nice to get these parts out of the basement and onto the car!!





Spent time today prepping the trunk for paint, still needs more elbow grease but coming along.



My new goals are to get the front trunk and engine bay complete, if I can get that done by end of April then when i get the suspension in I can think about getting the brakes hooked up. We shall see.....

[my928s4]

Getting the hang of the new gun and the color, certainly lots of difficult areas to get good coverage on.





I have the rear shox kit so I can weld in the brackets, next up is the engine bay and rear trunk.

[my928s4]

Rear trunk and engine bay painted, thinking how nice it must be to spray some flat panels ... running low on paint though. After I used the last of the toner they had I went back and they are going to try and get it from another store rather than try and match with the new unleaded formula.









Going to be out of town for a bit so nice to make a bit more progress.

[Root_Werks]

L20E, so pretty! (IMG:style_emoticons/default/smilie_pokal.gif)

[my928s4]

So finally got the correct Koni inserts for my Koni struts yesterday, was thinking I should wait to assemble but could not resist doing something with the new parts. All went together great except for the backing plate, I thought there was something wrong as it interfered with the rotor. After messing around for an hour finally figured out they were just bent, bit of tweaking and all is good.

Just need some tie rod ends and some wheels and it wil be a roller !!

When I was over at Renegade a couple of weeks back they had a car with the 17" Fuchs and they looked great, on my shopping list.

[my928s4]

Been out of town on a couple of trips so not much progress until this weekend, off on vacation in a couple of weeks too so good time to get some work on the car done!

I purchased some weld in nutserts for the foglamp, worked out pretty well and with those in place I could paint the front valance.





Also painted the passenger side door opening and the lower valance, finally getting the hang of the smaller gun so I can lay the paint on smooth without running.





While I was picking up more orange from the paint ship I bought some satin black, thought it would do for the interior, gas tank, rocker covers and other sundries.





Got some parts on order but my next goal is to get the brake system all hooked up, I have the replacement hard lines which should be fun. Hopefully I can work out where the old lines went, been a while since I removed them!!

[my928s4]

It has been a while, lots of smaller projects going on with the car which compete with vacations and projects around the house.

Finished re-bushing the pedal cluster, I got lucky with the pin, considering the condition I thought I was in for a fight but couple of taps with a BFH and it all came apart.

Before:



After:



I also took apart the shifter and replaced the upper sleeve, otherwise apart from cleaning it all looked pretty good.



Getting the brake system operational has been a goal for a while, it is all pretty much together and am waiting on the bulkhead grommets for the tubes from the resorvoir. Seems they are on backorder for the moment, once I have those I can finish.

Handbrake assembly in:



Handbrake cable and rear brake tubes hooked up:



Painted the rocker panel on the drivers side:



Started work on the doors, all stripped of hardware except the lower hinge which is proving resilient. Was going to get these blasted but had some left over stripper so what the hell.

[my928s4]

So had to add this photo, some parts make it feel like you actually have a car rather than a bunch of parts and the addition of the steering wheel did it for me. I was waiting on a new upper steering column bearing which arrived tonight, I had managed to get the lower bearing from a local retailer. Both of the bearings were toast.



I ordered the spring (Item No 7 in the pic below) as I thought I mine was missing but it did not seem to fit. Any ideas?

[my928s4]

I was cleaning up the seat brackets, thinking just a quick clean would be OK, ended up dismantling and prepping parts for paint and plating. This thing is a disease ...

Also tried bleeding the brakes but fluid leaked from where the front brakes go to the master cylinder, I had 2x12mm copper seals and one needs to be a 10mm. Back to waiting for parts.

So the progress on the doors in these pics shows a day an half worth of work, my arms and fingers hurt but at least I spent the time outside. Perfect weather and the dust isn't in the garage.

As you can see I managed to get one of the bottom hinges off, the last one is being real stubborn, I think an air hammer might work.

Drivers door had more rust at the bottom then the passenger and a couple of places need a bit of welding where the arm rest attaches as the metal is fractured.

[Black22]

First...I'm not a fan of Orange. That being said, that car IS and is GOING to be BEAUTIFUL! WOW! I wish I had the space, time and $$$$ to go that deep into rest. You should be very proud! Tired but proud! Great work. I'll be watching this until your done. I'm jealous. (IMG:style_emoticons/default/aktion035.gif)

[my928s4]

First...I'm not a fan of Orange. That being said, that car IS and is GOING to be BEAUTIFUL! WOW! I wish I had the space, time and $$$$ to go that deep into rest. You should be very proud! Tired but proud! Great work. I'll be watching this until your done. I'm jealous. (IMG:style_emoticons/default/aktion035.gif)

Thanks, still have to wonder sometimes whether it is ever going to get done, be nice to (IMG:style_emoticons/default/driving.gif) but still got my imagination.

[my928s4]

Finally got the brakes to a point where they are not bad, still some air in there but good enough for now. Took an AGE to get some of the air out, the long tube method is the way to go .... the wife and kids were taking a beating.



Also rebuilt the CV joints, one is toast though, nasty wear mark. Remember regreasing the ones on the 928 and all the mess, same all over again!

Can see the wear mark below



Got a nice package Wednesday, my 17" replica Fuchs arrived.

Rears fit great



Going to need spacers at the front though, 1.5".



Good news is that the tire to fender gaps are the same from side to side, was worried that those fenders may have had some variability but looks like I am good as far as that goes.

[Derek Seymour]

Why is this website the shit?

Example A your honor.
(IMG:style_emoticons/default/drooley.gif) (IMG:style_emoticons/default/pray.gif)

[arkitect]

(IMG:style_emoticons/default/beerchug.gif) Chris,
Great pics and description, your car is looking better than new, excellant job.

Dave

[charliew]

Nice job and good attention to detail.

[my928s4]

Thanks for all the comments, it helps keep progress going!

Found some Dynamat I had left over from when I did the 928 so decided to use it and clear some shelf space!



Looks like we have one last week of good weather before fall hits us so decided to get some painting done while we are still above 70F.

First job was to clean out the windscreen channel, the black sealant is tough but a few application of paintstripper and then the wire wheel did the job. Sealed the rusty areas with a suitable converter





Epoxy and 2K Primer finished the job.



Out with the epoxy and paint for the inside of the doors, the outside also got a final coat of 2K primer.





Also painted the seal channel in front of the windscreen.



Finally painted the drivers side door jamb, decided to mask the VIN sticker, came out OK except for some minor bleeding which I will see if I can remove. If not no big deal.

[Cj Honeycutt]

Looks like you got yourself a real project... good luck

[Root_Werks]

Nice to see some pictures.

Love how detailed you are getting inside the doors, trunks etc.

Looks great!

[andrewb]

Love what you're doing Chris, I'm right behind you.



For years I've been looking at my car and thinking it was all too much but now -a little bit at a time - I've starting doing things. What I like about your thread is that I keep 'seeing' my car and 'my' bits of rust in your pictures - it's that damned orange paint -which I'm also removing bit by bit but I won't be putting it back.

I have a question - those little 'rust spiders' - what do you do with them ?



I've been giving them a hard time with a wire brush on an angle grinder until there's not much more than a bit of discolouration but I'm now wondering whether I should keep going till even that has gone. What do you reckon ? If I don't get rid completely will they come back ?

Cheers, Andrew

PS Where did you visit in England ?