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Turbo restoration!

sulzeruk

Active member
Evening gents, thought that it may be of interest to keep a resto diary of the cheap 250 Turbo I bought a few weeks ago. There will be quite a few jobs I will be doing that I am sure others will want to know how they do them!

Got the car up on the ramp to have a good look round it and start to get the back axle out for the inevitable sill repairs!
Starting at the front, the wings had the usual rot at the bottom and also have had some poor repairs done round the edge in the past. The usual rust trap plastic bottoms were full of earth and other road debris and came off quite easily. I also took the other main trims off which actually fitted quite well. All bar 2 of the mounts broke off!

250turbo4.jpg


The back end of the sills had a bit of bubbling on the outside but nothing major. After a good poke with a screwdriver, there were a few holes but nothing irretrievable! As usual, the V between the inner and outer of the back arch was history! The rot is very localised so should be an easy repair! As can be seen, the main suspension mount bush is getting squeezed with the corrosion so is another reason to drop the back axle! I had a tentative go at loosening the main retaining bolt for the back suspension and both sides freed off easily, the bolts are usually rotten and always sheer. Certainly makes it easier to drop the axle!

250turbo1.jpg


250turbo2.jpg


Not much metal needs replaced here. The drivers side always seems to be better on these cars for some reason!

250turbo3.jpg


The pass side had faired a little worse, the inner has a smallish hole in it (the black dot in the above pic) and the V is gone!

250turbo5.jpg


The underside of both back arches felt a bit thin too and the above was the result of some poking with the screw driver. The underside spoiler will have to come off to get in to repair both sides.

250turbo7.jpg


One other thing that I had noticed was that the aluminium top mount had disintegrated on the drivers side. The aluminium had completelty gone just leaving the rubber sandwich.

250turbo8.jpg


As can be seen, the back end is a bit grotty. There is a lot of galvanic corrosion as usual between the metal and steel of the back axle assembly so all that will come apart and be grit balsted and painted. The car still drove very well apart from an extremely stiff gearchange and crap brakes!

250turbo9.jpg


This may explain why the brakes were not very effective. Both back disks were like this, the fronts were just as bad. The back calipers also had pretty extreme plate lift. All disks and pads will be replaced as well as the calipers being refurbed.

 
Good work Alasdair. Those sorts of pictures give me nightmares.
Your a brave man - please keep documenting the repairs so we can see how to tackle these type of jobs with the same enthusiasm as you.


 
Reminds me of my brakes! After weeks ofd trying to be a cheap skate and buying 2nd hand, bit the bullet and bought all new, well worth it in the end.

Good amout of work to do, but not as bad as some youv'e had in I'm sure, look forward to the next installment
 
Alasdair

What happened to the S2 in your earlier thread, did it get repaired or scrapped ?

http://www.porscheclubgbforum.com/tm.asp?m=547434&mpage=1&key=
 
Hi Jim, that S2 was too far gone. It had sat under a tree in the guys drive way for 3 years. There was no inner sill left on the near side and the front jacking points had vapourized. Someone had tried to jack it on the sill so I think that is what had caused the damage. The engine was also very well past it as it had burst the camchain and sat with the head off for the 3 years.
Alasdair

 
Scotty, the car is actually very sound, as I have said the interior is very good just needing a clean and the rot is actually very good for a 944!. It also has a nice bridge spoiler too! The engine is also sweet as a nut and clean under the bonnet. Needs a water pump and belts anyway! Will change the engine mounts as a matter of course!
Alasdair

 
Keep up the good work Alasdair, just love these resto projects.

My Guards pink Lux has just been despatched to the body shop today. Fortunately very little rust to sort out and none on the sills, cleanest sills I've ever come across inside and out. The only reason for the respray is really to restore the colour and get rid of a few dings and blemishes.

AD363192EA62415DA67D20609F073003.jpg
 
Hi Jim, I have a nice low miles S2 waiting for some body work (sills again!), it is also a fetching shade of pink at the moment. The early cars are far better bodywise than the Turbos and S2s.
Alasdair


 
ORIGINAL: sulzeruk

Hi Jim, I have a nice low miles S2 waiting for some body work (sills again!), it is also a fetching shade of pink at the moment. The early cars are far better bodywise than the Turbos and S2s.
Alasdair

Yes, apart from the plastic trim along the bottom of the wings and sills, is there any other reason for this, afterall the general theory is that they rot from the inside out, maybe the galvanising was better on the earlier cars.


 
There are loads of dogs out there, I've seen a lot of them. When I looked before I bought my Lux I looked at about 10, they were all rotten and in a lot of cases the owners genuinely didn't realise the extent of the damage. They just thought a couple of blisters on the sills were easy repairs without knowing the full extent of the rust on the inside. Inner and outer sills can be repaired fairly easily, but one the rust has got as far as rear suspension mounts its much more involved and depends whether the car can justify the expenditure, if its a good Turbo or an S2 then maybe yes, if its a Lux worth 2K maybe not.
 
Great pictures and write up, regarding all the rusty bits - you're a braver man than me !

Just a quick question for all concerned: How easy is it to remove the rear axle from a 951 ?

The reason I ask is that having had the engine and gearbox rebuilt, the sills done, the suspension refreshed etc. the last major job to do on the car (excluding fitting a roll cage....) are the fuel and brake lines.

My understanding is that its necessary to drop the rear axle to do this/ or use flexible pipes for the fuel line connections ?

I have no worries about doing this job as it 'looks' relatively straight forward - but thought I'd check ?
 
Edd, you would be surprised how many rusty 944s there are out there. I think the galv was better on the earlier cars and the metal was also better quality, I think it all came from Ravenscraig in Scotland. Heard that rumour many moons ago, don't know if it is true??
The biggest problem is the moisture getting in behind the underseal and stone chip and also moisture inside the car, leaky boot seals, etc, etc!
Chris, the axle is an easy job to get out. Remove the back exhaust section, remove the 2 main mounting bolts at the front followed by the 3 that hold the curved metal arms and the alloy mounts on. Support the axle with a transmission stand. Remove the handbrake cables and the brake lines and ABS sensor wiring and also the drive shafts. Should come straight out after that, will take pics when I get the turbo one out. I have to make a body stand first so I can keep my ramp free when the axle is off,
Alasdair
 
think the galv was better on the earlier cars and the metal was also better quality, I think it all came from Ravenscraig in Scotland. Heard that rumour many moons ago, don't know if it is true??

Interesting. I was told by the owner of the GTV6 on the 911PW shoot the reason why Alfas dissolved before your eyes in those days. When Fiat gave Lada their old tooling, it was paid for in recycled Russian steel, of the worst possible quality. I remember my Dad's first GTV coming from the dealer with rust in several places, and failing it's first MOT on corrosion. [:eek:]
 

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