Getting ready to put the finish coat on

The painting has started

nearly ready to paint

The last of the 928S trim has been removed

The last of the 928S trim has been removed and the car is almost ready to paint I have managed to find the rear 1/4 window trim and it will arrive early in the new year and will need to be re finished.

The body work is progressing well and I am really looking forward to seeing it painted, as far as I am aware it is the oldest 928 in our group and there has been a lot of interest in it's progress.

Body repairs continue

The body repairs continue it seems like it will never be completed but everyday we make a little progress, as the photo's show we have repaired the rust and the previous poorly repaired areas. The holes that were left after removing the "S" type spoilers have been repaired and metal finished

Body repairs continue

Rust out and new metal in

The rust repairs are progressing well we have made a new panel to replace the rusted out section, shaped and beaten by hand it's a good job and wont require any body filler when finished. I am lucky my panel beater is a very good tradesman and I am always keen to watch the restoration as it progresses

The restoration of the 79 5sp is progressing well if not slowly, the rusty section has been sand blasted, and it does look better now that it's clean.
We will need to make a decission whether to repair it, or acquire a replacement rear 1/4 panel and do a cut and shut repair. There has been good news I now know for sure that I have a genuine 79 rear hatch, we found the 928 pressed into the rear window surrounding trim, we now know that a "S" type spoiler was fitted to the original 79 model hatch after market and not swapped for a later model hatch, all very important when you are returning the car to it's original 1979 trim.
While we are on the subject of original trim the Pascha fabic that was in the original interior seat inserts etc has arrive from Germany it is Brown / Beige check, it will look fantastic when the car is retrimmed most likely early next year now as we have had a few set backs and we are about 3 weeks behind schedule

body restoration continues

The restoration of the body and the preparation for the respray has started, the poor repair I was told about when I brought the car has turned out to be a real shocker, as the photo's show just bogged over the damage there is rust well established on most of the rear quarter panel but we will hit it with the sand blaster and see where we go from there.
This is the the 4th or 5th total respray that Trevor has done for me and they have all turned out excellent I can't see this one beening any different.
I hope to have the respray finished before the end of November. There is still a slim chance that it will be finished by Christmas although the Pascha trim has not arrived from Germany yet and the body trimmer will need about 7 to 10 days to complete the interior

The restoration of the body starts

The mechanical restoration is complete

The mechanical work is completed and the car is registered and roadworthy and today I took it to the panel beaters to have the phoney 928S bits removed and restore the body to the true 1979 style.
I have purchased the Pascha interior material from Germany and spent yesterday in Melbourne having Gary Blackman Trimming go over the car to quote on restoring the interior they will need the car for about 2 weeks to complete the restoration.
So 2 weeks at the painters and then 2 weeks at the trimmers and its all complete.

The car has been registered for a week and I have driven it about 1000kl it drives beautifully and the ride and handling are first class there has only been a few small problems speedo failed and the amplifier was causing a very loud noise intermittently the speedo was easy the plug came apart enough for the electrical circuit to brake it's fixed but I will get the later model plug that clips together and needs to be manually unclipped to separate.
The amplifier has been disconnected and we will search the internet for a wiring diagram and then try again but at the moment it works quite well unamplified through the front speakers.

It's home

Lots has happened since my last post the 79 5 speed is home Chris and I went to town last Thursday and brought it home and also brought back what was left of one of the donor cars we used for some parts.
The car drove beautifully and although it showed up a few problems there was nothing to stop it from passing the roadworthy certificate today.
Over the weekend we had a major festival in town and I was asked to put my cars in it so I had the all together for the first time. I will register it Wednesday and I will drive it around for a week then it's of to the panel beaters for a respray.
Chris ordered the new Pascha velour interior fabric from Germany for me today EU79.00 per metre which I thought was a bargain being previously quoted AU$220.00 per metre plus $100.00 postage.
So we are on track to have it finished for Christmas.

It's the last 1% thats hard to find

The mechanical restoration is all but over we just need a few bits to finish it and make it roadworth we need a defuser for the r/h spotlight, the top of the w/screen washer bottle,and the tubes and the squirters, also a rear vision mirror, and a couple of bits for the door locks.
The car has been washed and polished for the first time in ages and the paint is in pretty good condition mainly a few stone chips.
I believe the parts are coming from a car that is yet to be wrecked hopefully they will arrive this week.

After 9 years the 79 5sp takes to the road again

My mechanic phoned today to tell me that he had taken the 79 for a test drive, so for the first time in 9 years my 1979 5sp 928 is up and running. On the road the only problem is no syncro on first gear but I dont see that as to much of a problem.
I will go down to Geelong in the next few days and bring it home.

More electrical problems

The electrical problems have continued to cause problems there is extra wiring everywhere the radio was wired in and the amplifyer was just stuffed under the passenger seat only half the speakers are wired to the amplifyer and there is wiring stuffed under the carpet some of which has the insulation damaged by being under foot.
We have fixed the ignition switch and have separated the excessary and start positions,
the wiring is so bad I can't believe that it was done by an auto electrician.
We have had a few wins the head lights and indicators are now working properly the control unit for the dash warning lights is also in and evrything is working.
everyday we manage to move forward although sometimes by not very much.

The end of stage one draws nearer

With any luck I will bring the 79 5sp to Portland Friday we had a small set back today when the bolts holding the thermostat housing broke and needed to drilled out.
The warning system controller arrived and was installed all the dash warning lights now work and the fuel gauge is also working after having fuel in the tank for the first time in 9 years.
All that remains now is to finish the thermostat housing cleanup the spider and refit, install the remote locking system and the engine immobiliser to keep the insurance people happy.
And then it's the start of stage 2 restore the body work and repaint

We fire up the motor

Dispite a few wiring problems we fired up the motor today seems to run well and good oil pressure we have a water leak around the thermostat cover an O ring has dried out and cracked we will get a new O ring, gasket, and thermostat tomorrow and give it a road test.

Electrical problems

we have struck a real disaster the wiring has been vandalised and it looks like the dash has been attacked by a mad man with a pair of side cutters, all the instrument warning lights are not working or disconected the loom has been cut in places and there is heaps of non genuine wiring and relays that we have taken out.
We have started at the electrical relays under the passenger floor and we will trace out each circuit and with any luck we will be able to trace all the breaks in the loom.
Saddly this has put us back a few days and could be the costliest exercise so far time wise

Good news bad news

The missing parts continue to cause us delays but we have taken the radiator into Ballarat and had it pressure tested it passed the test with no leaks and has been painted and refitted the distributor and the plug leads and conectors tested perfect.
We half expected the clutch to be seized but it worked perfectly as soon as the fluid was added and bled we were also able to select all the gears, the new battery has been installed as has the new electric aerial.
The ignition switch that was on the front seat in bits has been put back together and is working well and the instrument pod has come back from the Dash Doctor and is like new.
The new rear wheels have had the tires fitted and the front wheels have been painted and their tires fitted, all have been balanced and are ready to fit. I have found a set of the special wheel centres with the brass coloured crest inlays thanks to the help of the Landshark list members and Alex at Porsche Centre Melbourne. Maybe we will get it fired up this week but regardless every day we move forward a little :)

assembly hassles

We have found a few problems putting everything back together there are lots of bits missing nuts, bolts, and the odd bracket or two. Don't you just hate trying to assemble something that has been pulled down by someone else and left standing for years so many small bit have got lost :(
We have ordered replacements and the supplier is sending them over night we are still hopeful of firing up the engine tomorrow.

A big step forward

My 79 5speed took a big step forward today the motor is back together the brakes and the clutch have been bled and we are now shopping for a keyless entry system an engine immobiliser an electric aerial and a new car battery all being well it should hit the road around Friday.

Progress on the engine

The motor has new seals in the front and a new water pump everything has been acid dipped and cleaned up we are being held up because we are waiting for a washer/spacer and then we can re assemble the rest of the engine.
The suspension is finished and the new wheel bearing carriers and the wheel bearings have been assembled

Slowly it's coming together

Another shipment of parts arrived from the USA today 2 fuel pumps, engine filters, spark plugs, 1" spacers for the rear wheels.
The clutch hose was custom made in Geelong and that has been fitted we can now bleed the brakes and the clutch.
The instrument pod has been removed and sent to the Dash Doctor to have the vinyl repaired also the internal rear vision mirror has been taken off the w/sceen to have a new mirror cut and fitted.
The new 16"x8" phone dials have arrived from Germany and I am painting the 16"x7" front wheels ready for some new tires that I took from the S4 when I went to 17" wheels ( cup 1s ).
The engine has been cleaned and reassembled with the new timing belt,water pump, and all the front seals were replaced while they were exposed, as soon as we have the electrics sorted out and the new fuel pumps fitted it will be time to fire it up the first time in 9 years should be interesting to say the least.
I have booked the car into my panel beaters for respraying in October

Impact damage to the wheel bearing carrier

Rear wheel bearings

we found there was a problem with the drivers side rear wheel, on further inspection we discovered that the wheel bearing had been replaced at one stage, and the new bearing was installed using a very large hammer, all but destroying the wheel bearing carrier.
A new carrier was available from Porsche $1750.00 plus GST so a used one was found for $500.00. It arrived today and the new bearings were fitted and we are ready to reassemble the rear suspension.

Suspension and Brakes are finished

The suspension and Brakes are finished all the new parts are in and the rest have been cleaned and repainted so everything is black and sparkling clean. The brake calipers have been acid dipped and painted with heat resistant paint ( 1500deg )and all that is left is to bleed the clutch and the brakes and then its on to the motor.

The motor has sat for 9 years with out any fluid in it, so we are expecting to have to strip it down but we would like to run it first so we can assess the gear box etc by taking it for a short drive, we will know more in another week.

We have struck a small problem 30 years of rust and not ever being touched the front drivers side top control arm bolts are stuck fast, half a tin of penetrene and some serious contact with a mash hammer over a few days and still no joy.
We must get them undone to remove the old shocker and install the new ones.
We have found that the alternator is a none genuine job thats been fitted and rewired very baddly I will sauce a new Paris Rhone alternator from either 9 Spares in Melbourne or 928 international in California I would have preferred to get one from Roger at 928sRus but I have not heard from him.
Roger got in touch today and the Alternator is on it's way from Texas by priority air mail.

My mechanic phoned today all the new brake parts ( new disks,disk pads, hoses, caliper overhaul kits )arrived also the tie rod ends, and CV boots. The shock absorbers have arrived from the USA and I will drop them off on Tuesday I am still waiting for a clutch slave cylinder and a clutch hose, the hose seems to be no longer available we will get one made.
As soon as we get the brakes and the clutch working we will work on getting the motor running as far as I am aware it has not been driven since 2001 could be an interesting exersize.
We have given up on the S4 brake modification could not buy calipers so it is standard 1979 928 brakes excellent in there day anyway and many 1000s of dollars cheaper than the S4 conversion.