Suby-engined rustoration, 21-Sep-2024 update: more racing-related carnage! |
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Suby-engined rustoration, 21-Sep-2024 update: more racing-related carnage! |
strawman |
Apr 18 2008, 12:19 AM
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#1
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Senior Member Group: Members Posts: 885 Joined: 25-January 08 From: Los Osos, CA Member No.: 8,624 Region Association: Central California |
Hi All --
This is my second post, but I've been lurking on this fine website for a while now. I've wanted a 914 since I was in high school, but always seemed to stumble upon other projects... until recently. My neighbor gave me this 1973 Porsche 914 about a month ago. He told me he blew a head gasket and parked it in his parents' driveway in 1992. When his parents finally told him to move it or they were calling a local junkyard, he offered it to me since he knows I'm a gearhead. In for a penny, in for a pound... I hauled it home, knowing that it has some rust issues in the battery area and rear trunk. But it appears to have never been in a wreck and it is complete. It turns out that an exhaust stud pulled, so he coulda fixed it for a couple hundred and probably kept another 914 from languishing but I guess all things happen for a reason (namely, so I would undertake this project!). I sold the engine to a local Craigslister for use in his Meyers Manx dune buggy, and bought a wrecked but running 1993 Subaru Legacy turbo wagon. This is the closed-deck 2.2 liter engine, and 250 hp is easy with boost control and an open exhaust. I've already done a Subaru into a VW Vanagon and my daily driver is a 1992 Suby Legacy, so this won't be too much of a stretch for me. I plan to use the Suby 5-speed transmission (out of a 1998 Suby Forester) with the Aussie-sourced RWD elimination coupler and custom-mated 914/Suby axles. I've got a suburban home with a crowded two-car garage (my 125 shifter kart and my daughter's FJA kart will likely get lonely!), a MIG welder, and a wide assortment of air/power/hand tools -- so the adventure begins! This project will likely take a year to finish, so please be patient. I've attached some pics of the car as found in the driveway, some rust areas and the rear trunk repairs I've started. I'll chronicle the build as I go, so feel free to chime in! Geoff Attached image(s) |
strawman |
Apr 26 2009, 10:30 PM
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#2
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Senior Member Group: Members Posts: 885 Joined: 25-January 08 From: Los Osos, CA Member No.: 8,624 Region Association: Central California |
I knew there was a mess under the passenger side sail just above the door handle, as it was perforated already. But once I got underneath, I can't believe EVERY 914 is not rusting through in that area. Here is a pic before I started cutting metal.
And here is the culprit. Complete nastiness! That chunk of sealant traps moisture against the metal, inviting rust-through. I dug away as much of the sealant as I could reasonably get to and until I found clean metal underneath. Then I POR15-ed the area and the patch, which I cut from Martin Baker's (I can't remember his 'world name!) parts car several months ago. The patch piece was rusted on the back side, too (go figure!), but it was salvageable though thin. I welded it in, using the same tack/cool/tack method described in the post above. One additional challenge is that the quarter panel seam and door jamb (just above the door vent) is brazed by the factory, then leaded for smoothness. So I had to carefully grind away all the brass and lead to give me a good welding area, but I still got a lot of popping and burn-through trying to join these two pieces of metal. The welds are pretty "snotty," but they'll hold and the snottiness will be hidden by bondo before paint. Here is an after shot prior to primering. Next up is preparing to re-install the lower passenger side quarter panel that I had to cut out to make the hell hole repairs described earlier. Guess what? Yupper, I found some more rust! Attached image(s) |
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