Starting to Build It Back Up Again

Now that the body is back from the shop and I have the first load of electric conversion parts, I can get started on the main event - making an electric car!

Well, I immediately got sidetracked a bit.  When I got the body back from the shop I noticed a small number of points on the body that need to have the paint touched up.  I left the car on the trailer in case Rainbow wanted it back in their shop to do the work.  Now remember I live in an area that gets about 4-6" of rain per year, and it mostly comes between December and February.  Well guess what happened while I was down in LA working on the installation of a monitoring system for my company REC Solar?  It rained.  And the rain got into everything.  Most of the car was OK, but the floor of the passenger compartment wasn't primed and painted, it just had the original coating from the Porsche factory, which is 37 years old and not in the best shape.  It's amazing how quickly the rust stared forming!  I started working on scraping the coating back to clean metal and dry everything out.  When I'm sure it's dry, I'll treat it with the rust converter fluid.  When that's done its work, I'll spray on a new fresh, full new coating of the mystery stuff on the floor.  It seems to be a rubberized undercoating-type compound; I'll check out my options at the auto parts store tomorrow.

I removed the doors and front hood to make sure they don't get scratched during the conversion, and it also gives me greater access to the parts of the car I need to get to.

The pedal mounting area doesn't have a drain hole and the water pooled up nicely.  I had to remove the unit so I can get access to clean and de-rust the area.

Buying the remaining conversion components

Since we're so close to getting the car back and getting the electric conversion kit, I'm ordering the final components I'll need in the conversion process.

First up is a great piece of kit, a replacement fusebox from JWest Engineering.  The original fusebox uses Good-And-Plenty shaped fuses that are held in place by a tiny amount of friction.  The new fusebox has modern blade fuses, and bolts directly in place of the original.  For only $105, it's a great product that brings the electrical system up to modern standards.

Next is the PakTrakr battery monitoring system.  As I've written before, I've chosen this product to monitor the battery pack and have written a custom application for my Droid phone to display the data generated by the PakTrakr in a graphical manner, while tracking real-time trip distance and remaining miles on the charge.

As I've also written before, I'm abandoning the spare-tire-air-pressure-windshield-washer system.  I spent many hours trying to retrofit a tiny electric switch where the washer fluid valve was mounted in the windshield wiper / blinker mechanism inside the steering column.  Trying to make a tiny yet strong custom bracket just wasn't working out, so I started searching around for a Porsche 924 mechanism, which includes the electric upgrade.  I grabbed one for $50 on eBay, which is a great deal.  As a bonus it looks like the horn contacts are in great shape too.

I ordered a strip of basketweave material for restoring the dashboard.  The dashboard in my car has been hacked over the years, so this should give a nice clean look.

In the near future I'll be buying a Kenwood KDC-BT945U stereo.  I've chosen this unit because it has a USB cable that I can connect to my Droid.  This will allow the stereo to play the songs stored in the phone, and keep it charged while driving.  It also has a Bluetooth connection to allow me to make hands-free calls, with the caller's voice coming through the speaker system.

At Long Last, Ready for the Body Shop

Sorry for the long time between posts, but not much has happened physically on the car.  Our winter was very rainy so I didn't get a lot of good weather to do work on the car.  I did spend a lot of hours on improving the code for the Android battery pack monitoring app though.  It's pretty much ready to go, waiting for real batteries to watch.

When the weather broke a couple of weekends ago, I dove back in and removed the flywheel from the engine.  I installed the flywheel lock and it came off very easily.

 
Then I got the rest of the car stripped.  The only stuff I can't remove is:

- wiring harness - don't want to pull it if I don't have to as it snakes all over the car
- brake fluid reservoir and brake lines - again, don't want to
- drive shafts - the axle nut is frozen on both shafts.  I've tried WD-40, Liquid Wrench, a heat gun and a 2' breaker bar on the socket.  I hope the body shop can get these off because I'd like to clean them up.

I've found a highly recommended body shop right here in town - Rainbow Marine/Auto Body & Painting.  No web site, but phone is (805)239-3791.  They're going to media blast, repair the rust spots, prime, undercoat, paint and clear coat it.  My buddy Gary at G-Rides does a lot of work on a Porsche Turbo that is painted "Meteor Grey Metallic".  It still keeps the silver theme on my car, but a darker, more metallic shade.  I think it will look really good.

Here are a few pictures to show the state of the car before it goes off to the shop.  I promise I'll peel off the carpet first!

Well that's it.  More details as the shop gets to work.

Bumpers and Interior Removal, Brakes and Suspension Check

Yesterday I removed the front and rear bumpers.  Very straightforward, no surprises.

Today I worked on pulling the interior.   Some easy, some tricky...

First I pulled the two seats, with four bolts each.  Then I worked on pulling up all of the carpeting.  First I removed the defroster light fixture, then loosened the small setscrews holding the shift knob on, then pulled up the center hump carpet.  Then it got tricky because the steering wheel shaft goes through a hole in the carpet, so I had to unbolt the U-joint just above the carpet hole.  This was tough as the shafts that come into each side of the joint are quite long.  I ended up unbolting both sides, then prying apart the upper fitting until I was able to slide it up far enough so it came off the lower shaft.  After that the carpeting pieces came up nicely.  Then I removed the seat back panel and the aftermarket 3-point racing harness seatbelts.  All of this work led up to the gutted interior.  I found a dollar bill and about another dollar in change, so the car is trying to offset the cost of this project!

Next I moved on to the steering wheel.  I recently bought the required 27mm socket.  I quickly realized that the nut was on very, very tight and I had trouble trying to hold the wheel and undo the nut.  I finally stuck a 2x4 through the wheel spokes and jammed it down into the passenger wheel well.  When it finally let go, it was easy to get off.  Then I removed the indicator and windshield wiper controls.

With this pulled, I can see the source of two problems I was having.  First, the copper strips that conduct the signal for the horn switch are actually worn through.  So those have to be replaced.  Second, I found that the auto-return mechanism for the indicator is broken.  There were a couple of broken pieces of plastic in the area, so I'll have to see how that can be fixed.

Next I thought you'd like to view the heart of the device that is insanity that is the spare-tire-pressure-driven-windshield-washer-system.

If you zoom in on the picture, you'll see a little black tab that goes into the in-and-out fluid connectors.  When you pull on the windshield stalk, this black tab is pressed into the fluid connector, allowing the fluid to flow.  Unfortunately, it's bat-shit crazy engineering.  I have a couple of choices - I can just leave this alone or remove it and mount a push button switch on the dashboard, or I can track down a 924 windshield control stalk that has an electric switch to drive the washer pump I bought.  I'll make the decision later.

Next I checked the springs and struts.  They don't look original so I may be in luck here.  The springs are .388" thick, so I'll be able to find out what load they can handle.

I'll confirm both of these upgrades with my contact at Strasse Porsche in San Luis Obispo on Monday.