Refresh/Upgrades

[Scooter 911]

I have been working side by side with a local outstanding wrench that many of you early car owners of a certain Gruppe will know, by the name of Bernie. My car (Millie) went under the knife Wednesday for a complete overhaul, including a complete and refreshed SC suspension and a high compression 3.0 liter with Webbers. Now that I have just finished the third solid day of work, I still have another four days left.

As of tonight, we have removed the entire suspension, pulled the engine, power washed the engine compartment, and reinserted an entirely new suspension including:

* A arms
* aluminum cross member
* Koni struts with 3.5 spacing
* Inserts
* 22 mm front torsion bars
* SC calipers and rotors
* stainless brake lines
* turbo tie rods
* adjustable spring plates with new bushings
* 29 mm rear torsion bars
* SC aluminum trailing arms

We stll have to do the following:

* paint the engine compartment
* install the 22 mm adjustable sway bars front and back
* install new 205/50/15 Goodrich T/A KDW NTs
* wire the engine for MSD
* break open and refresh the '72 915 transmission
* install transmission, possibly with LSD (?)
* install 3.0 - 9.8:1 compression and 964 S cam, new SSI heat exchangers and sport muffler.
* install new 21 mm master cylinder
* install new axles

I know I am forgetting a lot, but you get the idea. Why we were in there many unplanned things came up. Oil lines have to be fabricated, the transmission was leaking at the main seal, master cylinder was leaking, and bad axles, among other things.

I drove my car back from Ohio to Seattle in July last year, going the long way, down to Texas and over to Southern California, then up to Washington. This trip was just the beginning for Millie and me, and now, after this experience, I feel like I know this car better than any car I have ever owned. A big thanks to Bernie for showing me the ropes!

Here are some pics:

And so it begins:



Engine out:





Will keep you informed as things progress.

[Scooter 911]

Bad CV Joints:




Goodbye soundpad:



Front suspension:


Engine compartment after power wash:

[70SATMan]

Looking good Scott! I'm one jealous bastard.

[RSwannabe]

Ya know when you're done, everyone is going to want to be looking under Milly's skirts at her fancy bits.

[Scooter 911]

Thanks Michael. Just wait until I get that flat Prototipo in there!

Brooke, let them try to look. She will be too low to show anything.

[Scooter 911]

UPDATE: Got the engine compartment painted today, engine is just about put together, and the transmission is open and in pieces.

Engine: Oil lines came in today. Fan and housing is bead blasted and installed. Decided on using updated alternator and installed.

Transmission: Good news! The transmission was very clean and had no metal shavings. Checked the gearing and found that I don't have a stock 7:31. The combination of the small wheels, the 3.0 and the existing gears is going to be ideal for track application. This is a huge plus. I am also installing LSD while I am in there.

Tomorrow is a rest day, but we will be hitting it hard Wed, Thurs, and Fri.

One of the three new oil lines:




Painted engine compartment (looks better in person):


Transmission in parts:



Factory LSD unit:




Engine almost complete:

[Bert]

Looking good.

Thanks for the updates.

[RSwannabe]

Be sure to spray down those bead blasted mag parts regularly to achieve that really cool satin magnesium look. Its well worth the little bit of effort.

[kenikh]

That 3 liter is going to be slow in that heavy 911.

[Scooter 911]

Great pictures, I love to see Millie out driving around.

Update: I was only able to work on the car half day today (I have a day job). Ran into a few more problems with the LSD/transmission rebuild, but I think it will be worked out by the morning. This LSD thing is really getting expensive. Got the old master cylinder out and ready to put the 23mm Mercedes MC in. Removed the old short shifter to install the refurbished stock 915 shifter. Cleaned up the pedal cluster, which was a mess with all the old brake fluid and other misc. garbage.

I hope to have the 3.0 and transmission installed tomorrow, along with the new oil lines and cooler and sway bars. Monday should be new tires and alignment and corner balancing.

Today was Bernie's birthday...Happy Birthday Bernie!


Pics for tonight:

Shifter taken apart:



New 23mm Mercedes master cylinder:



Transmission almost back together: