A very good customer showed up last fall with one of my favorite cars, an early Porsche 911 Coupe. While the car did run and propel itself down the road, it needed lots of mechanical attention to remedy oil leaks, weak compression on a few cylinders and a huge list of other things. We decided that in order to enjoy the car in the future, we needed to go through the engine, transmission, brakes, clutch and other less dramatic things such as the heat and vent controls and … windshield wiper blades!

Here is a video of the engine running on the test stand to check for leaks and the adjustment of the ignition system and carburetors. This engine has German made Solex/Zenith carburetors, an Italian produced Magnetti Marelli distributor in combination with a French S.E.V Marchal Alternator.

Here’s a youtube link to see the engine running on the tabletop

Rebuilt 911 engine

We used to send these Overdrive Units off to a specialist to be rebuilt but something always went wrong on the first test drive. Come to think of it, sometimes they were leaking so badly that we had to take them apart and re-seal them before knuckle busting installation into the chassis.  Considering all the time to properly package the part, the cost to ship the 40lb crate as well as the weeks it takes to get it back, Nate decided to overhaul this Austin Healey 3000 Laycock deNormanville unit on his own. All the parts are available so once they arrive, he’ll slam it back together and test it by spinning it up on the lathe so he can be confident things are right before the installation.

Moss Gearbox

Overdrive Repair and rebuild

We often pick on people who say “all you gotta do is”, because there’s no such thing as “all you gotta do is”…. Anyone who says “all you gotta do is” either has never done it before or is trying to beat you up on an estimate. AKA, a looser

Most of the cars we work on have brand new brake components available to purchase which allow us to slam ‘em in and ship it. Unfortunately, we have to rebuild brake components on Ferrari’s which really sucks.  All you gotta do is…  Ugh. A guy sent me a totally blown out Master cylinder for a 330 GTC, rusted and stuck, terrible, horrible, so I sent steel fittings off to be cadmium plated, sent the cylinder to have a new sleeve installed in the bore, ordered an overhaul kit and when everything returned, I put it all back together. After assembling it the I noticed that the pistons were sticking in the cylinder so I took it all apart and the wrenches scratched the fresh plating and watched as the brake fluid stripped the black paint. I honed the bore and got the pistons to move freely, assembled it again and set it up to be tested on my high tech device that you can observe in the photo below. Now I am finding that the sleeve wasn’t drilled correctly and fluid couldn’t  into the forward chamber (that goes to the rear brakes) so I had to start all over again, scratching, chipping. Now, the cylinder is all back together and working perfectly after 7 hours of labor! “All you gotta do is”! Did I mention that the rebuild kit didn’t come with the correct first seal, there was a 30mm seal included when I needed a 25mm seal so after buying 3 kits, I resorted to making my own seal.

Ferrari GTC Brake Master Cylinder

It’s hard to tell how deep the crease is in the photos but the door skin actually split at the rear edge and crushed the framework at the closure area. The crease went on the panel behind the door as well so Nate took the door apart and pulled the fuel tank to access the inside of the rear panel. I had to make a few custom tools to get inside the door to shrink the sharp crease and other dents without having to remove the entire skin. It would have been a bear to remove and replace the skin because the door fits so well from the factory and to duplicate that is tons of work. A complete replacement door would have been equally intensive so my gut reaction is to fix what you’ve got

The paint match is excellent, the car is the newer tint of blue sera metallic, a slightly lighter shade than I have seen on older cars like Dino’s and 330′s. I like the older shade more because the paint contains more gray where the shade on this car has more         violet in the tint. Either way, I am happy with the results, the car is fully polished and looks killer

GTSI Door repair

Quattrovalvole 308 GTS

We did tons of work on this 1956 Jaguar XK-140 this summer, between waiting for parts and correcting some stubborn little details and then cleaning it all up, we spent some hours on this beauty. Now that Mike has his car back, he has been driving all over the place including to and from work, a 50 mile drive one way!

Jaguar XK-140 DHC

Here’s another 250 engine being assembled, we didn’t overhaul it but had to disassemble it to correct head gasket leaks, water pump leaks and replace the roller followers with the needle bearing type. We have had great results with the needle bearing style followers and but poor results with the bushing type which wear out in 600 miles! When an engine needs this much work we pull it from the chassis so it can be test run and inspected for leaks. Here are our famous formula head gaskets in use which have proven themselves reliable and consistent.

250 GT engine 27XX

Even though this Porsche 911 has been in Colorado from new, it has some major rust issues that need to be addressed. We had to replace the front suspension pan and decided to prepare the car for a full paint job after finding rust in the doors, the fenders and in the RH rocker cover. Overall, the car is super solid and clean, making it a nice project to work on and, when it’s finished, a wonderful early 911 Targa. As anyone who has been reading this blog knows, early 911′s are some of my favorite sports cars and feel that they are becoming valuable enough to justify putting some money into.

911 Targa Paint Job

Suspension Pan 911 Porshce

911 Susp pan Porshce

166 rear glass

Side glass plastic

Side glass profile detail

Even though the original rear side glass for the 166 fit terribly, I used them as a rough outline to make new pieces from plexi-glass. It still took 4 hours of sanding per side to get it to fit tightly. These windows open at the rear for ventilation and the reason Touring made them from plastic is to allow them to bend outward without a hinge as the cam mechanism pushes it out. Crude. In the photo with the drawn outline you can see the original shape being so much smaller than what it needs to be in order to fit properly.