Derek’s Willow Green, ‘72 914, Restoration Thread Options

[dereknlee]

Inspired by others on this forum, this thread will document the restoration of my 1972 914 1.7.

I bought it in summer of 2008. It was supposed to be my daily driver that I would make minor improvements to while keeping it drivable. There was a memorable couple of weeks where I was using it for my commute in the winter, with no heat (heat ducting/valves removed for paint), and then the ignition switch went out and so I was parking at the top of hills until I got that figured out/fixed. I don't know how 914s got on my radar or what drew me to this car. Le Mans was, and is, one of my favorite movies - so I thought 1970s Porsches were cool. 911s were a bit out of reach, so I guess the 914 was the next closest option.





[Side note, cell phone camera technology has come a long way since 2008....and these pictures make me feel old.]




The plan for this car to be a daily driver changed (not so much by choice) when I bought a house in the fall, and upgraded from apartment carport to an actual garage. I set aside a couple weeks to drop the engine and tend to some oil leaks, and of course - discovered rust. The car hasn’t driven since (12 years as of this writing).

The worst of the rust was in the hell hole. I bought a MIG welder and did a fair job of patching things up. I also attacked the rust at the driverside jack point and in the rear trunk.





Then the house remodeling got serious. The car sat for four years before I decided I wasn’t going to learn body work and the car deserved better. I hired Eurotech Bodywerkes to finish the rust repair and repaint the car. When I bought it, the car had been re-sprayed (and poorly masked) in a John Deer green. The plan was to go back to the factory color: willow green.

Eurotech found more rust in the doors, so it got new doors. They also fit factory sway bars. They fixed miscellaneous rust all over the place, filled dings, re-sealed the seams, installed a new battery tray, stripped the underside, fitted new rocker panel valances, restored the old front and rear valences and then laid down a very pretty paint job. The cabin and front tank bay are the only areas with original paint.








At the same time I had the engine rebuilt by NW connecting rod into a 2ish L displacement (not sure as of this writing whether it is a 1911 or 2056) with a carb cam. The plan was to fit dual Webers (more on that later). I also had the transmission rebuilt to fix a chronic 1st gear grind. And I had some parts re-plated.

And then the car sat for six more years while I permitted and built/finished an addition to the house, as well as picked up some sports to occupy my time.

Spring forward to Dec 2018, and a freshly separated shoulder from a cycling crash. I started working on the 914 again. Re-sealed the tank (the kits available for this are amazing).



And refurbed the wiring loom in the front trunk:



...before getting side-tracked again by a Vanagon. The Vanagon was a 2018 acquisition that suddenly needed a motor replacement in 2019, following a catastrophic failure that occurred a few days after this picture was taken.



Which brings us to the current covid quarantine times and cancelled vanagon trips. But on the bright side, work has restarted on the 914 again. (IMG:style_emoticons/default/piratenanner.gif) Will this be the final push that sees the car on the road? Track record says no, but only time will tell.



I will add additional posts to document progress. But at the outset I’d like to state my intentions with the project I would like this to be a stock 914 (IMG:style_emoticons/default/prop.gif) - at least outwardly. This presents a dilemma relative to my current 2L engine. I'd like to coax as much performance out of the engine and 1.7 L Djet system as I can. But a new cam is in order to even consider that, and as long as the engine is coming apart then I can re-think heads and displacement - with the aim to go as big as possible without ditching everything for a 2.0 L Djet or going microsquirt.

-Derek

[dereknlee]

Been a busy few years, but sadly not on the 914. It's once again covered in dust. This fall I picked up a Honda C70 passport that was in pretty rough shape and got it back running and looking good again.



I had so much fun working evenings and weekends on that bike. It was a good mix of mechanical tasks and cosmetic work. But I knew that I'd enjoy working on the 914 just as much. It's easier for me to lose momentum on the 914 because of the scale, and also because I care so much more about getting it just right. But there is only one way to eat an elephant, so I'm back at it.

Its strange reading some of the earlier posts or digging through the boxes of parts, because I have almost no memory of some of it. But all this time what has been front of mind are two leftover washers from the wiper mechanism install. They aren't called out in the PET, but I remember figuring out a few years back where they went and making a mental note to install them. Fortunately, the airbox wasn't fully installed and the posts can be maneuvered out of the hood without removing the dash bolt. So today, the washers are in and my brain can rest easy.



I also rekeyed the ignition, front and rear hood keys using a set of wafers that must have arrived from keys4classics about the time I stopped working on the project. I have no record of the original key code for my car, and know it was re-keyed at some point. So I bought a set of oem keys on ebay, then ordered wafers to fit that code - so that all the locks match a known baseline. I vaguely remembered that there was something wrong with my ignition lock mechanism, and found that I had sourced a donor (another "problem" as this project stretches on - I don't know what parts I already have lying around). So now, after 3 years, the ignition cylinder is back in the car. Also got the rear trunk mechanism re-assembled and installed.



With the rekeyed release handle, I installed a new cable for the front hood release. On my first attempt a few years ago, with 914rubber supplied wire and housing, I had introduced some bends in the line that I then blamed for the very high pull force required to release the latch. So this time I was very careful, and used a new oem cable assembly. But even with a cable that I am sure has no deformation, it still requires very high cable force to release.

A final item on my mind has been a mistake I made removing a stuck bearing from one of the wheel hubs. Circumstances are hazy, but I know i had to cut it off, and clumsily ended up cutting into the machined surface. I blended it with a file and at the time thought it wasn't too bad - and looking at it today it isn't as deep as I recall. But still, wondering if it is worth finding a replacement - or would it be fine running as is?



-Derek