[rothaus]

Looks like I got the easy part done.

Now moving to the left side.



The support rail need to go, I patched it up 15 years ago.



Removed the rail, but WTF ??



More rust





Heating channel is also bad, as well the plate between the rail and the channel.



Not much left



Now I need a new heater channel, and the plate that goes between. Also some more pieces to fabricate.



More next weekend.

Cheers
Engelbert

[rothaus]

Still waiting for the heater channel. No, what can I do to use the time.

Axle shafts need new CV joints.

Here is the old stuff. I cleaned one to see what the look like.



New parts I had already ordered.





I go put the grease is when I install them. Now they are ready and I just put them away.



So now, what's next ? I thought, lets crack open the transmission, and put all new seals in. There was no problem, but it was leaking. Draining the oil.



Disassembly has started.





I had to build a little jack to press out the shaft.



Here it comes out.



The clutch lever gave me a hard time. But after a short fight he gave up.



Here is the housing cleaned and ready for paint.



And now painted with engine enamel.



More pieces to clean and paint.



Here it is, ready for assembly.



So far so good. I broke the clip ring for the main shaft. Also need to get some other small parts.



Hope to be able to assemble it next weekend, and then get back to the heater channels.

[N0tt0N]

What did you do AFTER lunch? Very nice as always. Did you use your sandblast cabinet to cleanup the casing or brush/scrub? I assume the casing is made of iron?

[Carrera51]

This is awesome. I wish I had the skills to do something like this.

[rothaus]

Originally Posted by N0tt0N

What did you do AFTER lunch? Very nice as always. Did you use your sandblast cabinet to cleanup the casing or brush/scrub? I assume the casing is made of iron?

Actually, after lunch I washed and waxed the Boxster.

I bead-blasted the casing. Based on the weight, I think it's magnesium. The Porsche casing is much heavier.

[roundel]

Is that retaining ring seated properly on the axle? It doesn't look in the groove in that photo.

[rothaus]

Originally Posted by roundel

Is that retaining ring seated properly on the axle? It doesn't look in the groove in that photo.

Good eye !

Agree, not in the picture. I always check them with a flashlight, to see if there is still a gap between the ring and the bottom of the grove.

[rothaus]

Time for an update.

Still need to get some of the Transmission parts. In the meantime the heater channel came.

Here a few picture during cutting out careful the old rusted pieces.



Laying the whole thing at the side like this makes it so much easier to work on it.


Turning it to the position so it's comfortable to work.



A section of the old channel is gone, and so some other rusted bits and pieces.



Finally, the complete heater channel is out.



Now the challenge starts. I sandwiched together the support rail and the heater channel, and the holes do not line up.



The rails are made in Germany, the channel is made in Danmark.



Looks like I have to do some fitting of these holes, between the channel, rail, and the floor pan.

Also the front end piece I had to flatten out, because it was too short.



I put in some bolts between the rail, floor pan and channel, and here goes the first test fit.



Some pushing and wiggeling and it actually doesn't fit that bad.



Looks like I need to fabricate some pieces to fill in the holes, LOL.



Checking the inside, and it doesn't look that bad, as well the measurements of the door opening.



On the front side I have to make some pieces. I got the outer skin, but there are some pieces to fabricate. A little more as it was on the right side.



Here it is fitted in. Next weekend I will check it out again, mark all the holes which need rework, and if it's all good, tak-weld in the channel.



One last look on the RIGHT side, to see some positive things, and then it was time for a nice beer.



Cheers
Engelbert

[N0tt0N]

Do you allow spectators?!

[Lupin..the..3rd]

Originally Posted by N0tt0N

Do you allow spectators?!

no kidding, he could charge admission and still fill the garage with people. very nice work.