Wednesday, 13 September 2017

Porsche 944 Back on the Road!

After nearly a year off the road being restored, my Porsche 944 now has a new MOT and is back running again. The car looks stunning in brand new Guards Red paint and all I need to do now are some finishing touches to complete the restoration.

Tuesday, 22 August 2017

Porsche 944 Fuel Lines Replacement - How to Replace Corroded Lines for low cost

I needed to replace the fuel lines on Porsche 944 and originally planned to get genuine Porsche parts. However having fitted the lines and tried to connect them to the rubber fuel lines in the engine bay I found that the lines supplied were not correct and were for a 16V model not the 8V that I have which meant the connections were in the wrong direction.
Photo of Porsche 944 rusted leaking fuel lines
Photo of Porsche 944 rusted leaking fuel lines

Unfortunately the correct lines were out of stock at Porsche with no estimated delivery date so without them I would be unable to get my car back on the road. The front sections of the lines looked fairly straightforward, the feed line was 10mm steel and the return line was 8mm. Steel wasn't an option but looking online it appeared that Kunifer alloy lines would probably do the job.

All I needed was somewhere to locate the correct fittings so I could join the new pipes to the existing. I was very lucky to find a company locally called Aghabridge based on Medway City Estate near Rochester. After taking the original lines in to them they measured the fittings and the 10mm pipe has M16 x 1.5mm threaded connectors and the 8mm line had M14 x 1.5mm. They were also able to supply and flare the 8mm and 10mm Kunifer tubing so that I could bend the pipe into the correct shape. I believe they can probably shape the pipes too but that was something I could do myself.

For the front section of the lines you will need:

2x M16 1.5mm fittings
1x M14 1.5mm fitting (only 1 needed as the rubber pipe in engine bay connects with clip)

122cm of 10mm Kunifer or copper line/pipe
132cm of 8mm Kunifer or copper pipe

The 8mm line is slightly longer due to the route it takes and the staggered nature of the join under the car.

Flaring tool or workshop to flare ends of pipe

I already had the rear sections of the fuel lines from Porsche but in hindsight could have used the Kunifer lines for the whole car which would have been a massive saving.

The Porsche lines in total are around £500. Kunifer with all the fittings would be about £60.

Sunday, 16 July 2017

Porsche 944 Rear Axle Bushes Replacement

This Powerflex diagram shows the different bushes to replace on a Porsche 944

Thursday, 6 July 2017

Porsche 944 Clutch Master Cylinder

The clutch master cylinder was leaking on my Porsche 944 so one of the jobs I've been needing to do is replacing it. I bought the part many months ago but with the other restoration work taking priority it's been left. Before I put the seats back in the car it seemed an ideal opportunity to sort it - and from the experience I'd highly recommend doing the job with the driver's seat removed!

The actual replacement of the master cylinder is fairly straightforward but was much simpler with the underside of the car dismantled. Without the exhaust and torque tube in place it was much easier to access the bleed nipple for the clutch to be able to flush the old clutch fluid out and remove air from the system.

When we did the bleeding the fluid that came out was a horrible brown colour so hadn't been changed for some time.

Thursday, 22 June 2017

Porsche 944 Rusted Sills Again

I recently had the rusty sills on my Porsche 944 welded and repaired at the Porsche 944 specialist Retro Restorer in Banbury.

While the work was taking place I visited the workshop to see how bad the sills were and to find out the progress of the repair.

At the time my sills had been welded and new metal fitted but there was also another 944 in the workshop at an earlier stage of preparation showing how bad and rusty the Porsche 944 sills can get

Thursday, 27 April 2017

Changing Leather Car Seat Colour

With the driver's seat in my Porsche 944 being very seriously worn I decided to get the front seats retrimmed and have had them finished in black leather with soft perforated leather inserts. The trimmers also built up the side bolsters so they are closer to the profile of the 944 Turbo seats which should make them more supportive when driving.

Photo of Porsche 944 seat retrimmed in leather
Porsche 944 seat retrimmed in leather

In order to match them I needed to get rear seats also in leather and found them selling on eBay for much less than it would cost to retrim the rear sections. Unfortunately the set that I managed to find weren't in the correct colour so I've needed to get them recoloured.

I found a site called Furniture Clinic that sell kits to recolour leather seats so ordered a kit to do the job. There are several parts to the process which includes abrasion of the surface coating with pad and solvent to remove protective layers followed by application of new colourant to set the new colour on the leather. 

The photo above shows the seat part way through having started to remove the coating with abrasive pad and solvent. I'm working through the process and will update with more info once I've got the finished car seats and new colour

Tuesday, 25 April 2017

New Fuel Pump Porsche 944

The original reason for stripping down the rear chassis of my Porsche 944 was to replace the fuel lines which were severely corroded. Before fitting replacement fuel pipes it seemed to make sense to also replace other components too so I've also replaced the fuel pump and associated filter. The pump appeared to be original so has done well with 31 years service and 180,000 miles of driving.

Old fuel pump
The old fuel pump showing the very corroded fuel lines into it. The pump is protected by a thick rubber housing that needs to be removed to be able to fit the new pump into it. It's a very tight fit but the end of the pump with the terminals should come out of the housing

New shiny fuel pump side by side with the old one