#3616344 - 04/02/09 01:52 AM
Dan's Porsche 912 Project
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DanTSiAWD
Poster
Registered: 09/13/08
Posts: 221
Loc: Bay Area, CA
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I bought a '68 Porsche 912 last week. For those in the dark, a 912's a 911 but has the 4-cylinder from the last 356. You can put the flat-6 in but I'll probably just keep it O.G. I now own 3 cars but will probably sell the Tal0wn soon to make space for this one.
Cliff notes: Picked it up cheap, original paint and motor, all interior and accessories intact. Rusty floorpans but not terrible, some rust on fenders but overall not in bad shape for a 40 year old car.
It wasn't running and the only other guy that looked at it chickened out at the sight of rust, but it apparently had only been leaking for a couple years, as it was parked outside and had bad seals. I had it started in about 20 minutes after bringing it back to the shop, but it wasn't driveable yet. It clearly needs a lot of work but I've got time and access to lots of Porsche parts and references... 
Huge pic from the manual which reads:
Judging by the car you have chosen,
you are a motorist of a special caste.
Although you probably are no freshman
when it comes to automobiles, we
have compiled much useful information
in the section entitled Operating
Instructions with which you should
become familiar before driving your
Porsche.
Additionally, the remainder of this
manual is equally important and we ask
of you to devote your attention to it
at your hour of leisure.
We wish you many miles of pleasure
and accomplishments in your Porsche
Dr.-Ing. h. c. F. Porsche KG
Stuttgart-Zuffenhausen
West Germany
The ad says "Doesn't run". Gee...
I removed every ounce of carpet, extra interior, and most of the insulation/sound deadener from the car already. It was all soaking wet from a recent rain. I'll be restoring an inch or two at a time at this rate but haven't decided on a game plan. For now I just want to drive it...
Hood was repainted at some point and looks really bad compared to the rest of the paint...
Ugliest part of the whole car:
Surgery begins...
First order... new brakes and caliper rebuild kits
Last weekend I tried to drive it, but noticed the gas pedal was sticking. I spent a few hours removing this monstrosity:
Throttle arm was completely stuck.
I had to drill a hole between the bushings and inject penetrating spray. Then torched it for a bit and eventually freed it up. The gas pedal flopped around though because it's just a big rubber pad on these cars that pushes a rod, so I had to replace it.
Fuel pump was acting up so I threw in a cheap electric for now.
This oil line was also leaking:
So I removed the distributor and replaced it:
Oil leak was fixed, but I noticed it's leaking a bit of gas, too. I ordered the rebuild kits for the aftermarket Weber Redline carbs today. I should have it tomorrow but probably can't get to it until Monday.
Current state is that it runs excellent and drives fine except the gas leak that scares me enough to let it stay parked and drive my Honda until I fix it... The wet interior's out and it's all dry, so the car smells a lot nicer now. I don't have much into it yet (<$5000) and won't go crazy, but I thought it'd be a fun car to kick around and maybe make a few bucks on if I sell it down the road.
I've even got some black plates for it but can't put them on until July when the new law takes effect. 
PS - One thing that amazes me is the quality put into Porsches. Of ~150 nuts/bolts/screws removed, not a single one has stripped or broken yet -- not even the rusty ones. The windows roll up great, the doors thud shut and feel extremely solid.
Edited by DanTSiAWD (08/01/09 06:47 PM)
_________________________
2001 MR2 Spyder silver needs to go to tracks 1968 Porsche 912 (carbd and shit) 2001 Honda Insight 5-sp stealthy silver DD. 1850 lbs S2K seats and stuff swapped in SOLD AP1 S2000 GPW/red, 1992 Talon TSI AWD (12.9@105), 1984/1986/1999 Mustang 5/5/4.6
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#3616458 - 04/02/09 06:28 AM
Re: I don't drink milk but...
[Re: pumpkin escobar]
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GrizzleHorn
Jr Member
Registered: 01/05/07
Posts: 648
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Very cool.. can't wait to see more pics as you work on it.
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#3616680 - 04/02/09 08:56 AM
Re: I don't drink milk but...
[Re: ewraven]
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Z24 lol
and Fuck you for the new name lol
Post Master Supreme
Registered: 06/08/00
Posts: 43359
Loc: Lovely CONROE, TX! YEE-HA!
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Congrats, great looking car. That car looks like a massively fun project! What is the difference with the 912 SE edition?
I saw one the other day and was surprised when it wasn't a 911; I'd never heard of a 912, except this one had "SE" after the 912 on the rear end.
There was never a 912 SE, there was a 912E though
In 1975, the world had been pitched into an energy crisis, with oil moguls OPEC having raised the price of crude oil by almost 400%. This made a huge impact upon the automotive industry, chiefly due to the rise in fuel prices warding off buyers from thirsty, uneconomical sports cars. This created a situation for Porsche - its model range was soley sports cars, and its biggest market was the USA, where the ripples from the oil price had the largest effect. To overcome the economy barrier, a new model was unveiled - the 912E.
The 912E was based upon old engineering. The car was essentially a Porsche 911 bodyshell, complete with the impact-absorbing bumpers, with the four-cylinder engine previously used in late-model versions of the Porsche 914/4 (based on the Volkswagen type IV engine). The car was only offered to the USA, where it proved a spectacular sales success. It wasn't fast, especially compared with the contemporary 911, but it was economical and looked identical to the 911. A year into production, the oil price had settled down enough to encourage Porsche to discontinue the model, and change its focus back to high performance cars. It responded by creating the 930 Turbo.
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#3617120 - 04/02/09 11:22 AM
Re: I don't drink milk but...
[Re: Impulsive]
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Serendipitous
Post Master Supreme
Registered: 04/30/01
Posts: 15299
Loc: Northern California
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Best thread here in a long time. Congratulations on your purchase and keep the progress pics coming!
_________________________
2023 Model 3 / 2005 S2000 / 2012 A3
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#3617138 - 04/02/09 11:29 AM
Re: I don't drink milk but...
[Re: pumpkin escobar]
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Agent Orange
Post Master Sr
Registered: 07/20/01
Posts: 6849
Loc: Suburbs of Colorado
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Seriously that is fucking badass. Very cool man.
Glad to see the progress pics of the resto, great work!
_________________________
"When I let go of what I am, I become what I might be." - Lao Tzu
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#3617232 - 04/02/09 12:09 PM
Re: I don't drink milk but...
[Re: Agent Orange]
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DanTSiAWD
Poster
Registered: 09/13/08
Posts: 221
Loc: Bay Area, CA
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Thanks guys, I wasn't sure what to expect but I'm glad you all think it's so cool. I've been lurking/posting here for ~10 years (under 2LiterTurboTimmy's account, or my friend Dyre (Dyre13T?) who had a FC Turbo II)... this is the second project I think I've documented on this site (last was an LS1 fox body that I ended up canning :)).
I will take many pics as I continue the work and I'll try to use a real camera next time instead of my phone. I'll get some video of it running after I rebuild the carbs. It sounds pretty cool and definitely authentically German.
_________________________
2001 MR2 Spyder silver needs to go to tracks 1968 Porsche 912 (carbd and shit) 2001 Honda Insight 5-sp stealthy silver DD. 1850 lbs S2K seats and stuff swapped in SOLD AP1 S2000 GPW/red, 1992 Talon TSI AWD (12.9@105), 1984/1986/1999 Mustang 5/5/4.6
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#3617289 - 04/02/09 12:27 PM
Re: I don't drink milk but...
[Re: DanTSiAWD]
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CommonGutterTrash
This user is more useless than a half-baked compost pile.
Post Master Sr
Registered: 09/16/02
Posts: 6437
Loc: Boston MA
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It Does look pretty nice. Definitely a project worth having!
I love the color, actually. My first volvo was a similar color.
good luck!
_________________________
Craig R. 2000 9-5 Gary Fisher Wagon 1995 850 T-5R 1996 Galant  AIM = gclipse96
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#3617367 - 04/02/09 12:54 PM
Re: I don't drink milk but...
[Re: SiAdam]
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DanTSiAWD
Poster
Registered: 09/13/08
Posts: 221
Loc: Bay Area, CA
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Very cool, indeed.
I normally don't say this, but I'd paint that before I did any motor work..lol.
Thanks, it actually looks pretty cool in person, like a flat tan from a military/desert vehicle or something. The color's growing on me more and more, and I think I can work with the paint (except on the hood) so it'd be a shame to just strip it off and re-shoot it. That's one thing I really dig about it... there's not some half-assed Maaco job on it.
_________________________
2001 MR2 Spyder silver needs to go to tracks 1968 Porsche 912 (carbd and shit) 2001 Honda Insight 5-sp stealthy silver DD. 1850 lbs S2K seats and stuff swapped in SOLD AP1 S2000 GPW/red, 1992 Talon TSI AWD (12.9@105), 1984/1986/1999 Mustang 5/5/4.6
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#3619381 - 04/02/09 11:58 PM
Re: I don't drink milk but...
[Re: DanTSiAWD]
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progressi
Post Master Sr
Registered: 06/01/01
Posts: 9133
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This car deserves more than a "milk" post! 
I love all your cars,except maybe the insight,but LOL maybe with volatile gas prices may be a necessary evil.
Do you have any regrets?
My current purchase was one idea of 4:
Evo X MR
C5 (dur)
911 SC
E36 M3 w/Euro ITB swap.
The one I think about the most is the Porsche. 
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#3620377 - 04/03/09 11:29 AM
Re: I don't drink milk but...
[Re: progressi]
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DanTSiAWD
Poster
Registered: 09/13/08
Posts: 221
Loc: Bay Area, CA
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The Insight's such a good car, but a lot of people dislike them. They're fun to drive though and get 60-70 MPG. Mine's got some bigger tires and it's a real kick in the pants to fling around town.
I put S2000 seats in it, too. Was thinking about building a turbo setup for it.. maybe some day.
There are 3 people at my shop and all three own an Insight in addition to 1+ Porsches.
But no regrets here, maybe selling my 99 GT a while back..
I'll miss the Talon (huge image) but its time has come and gone.
Evo X MR
C5 (dur)
911 SC
E36 M3 w/Euro ITB swap
The late-70s/early-80s 911s are so cheap now (seen many under ~$9k). They're pretty hot looking, but I hate smog (California) and they're a bit heavier than the older ones. Mid 80s are a bit better for power/features too. The 964s are much better but get up there in price.
I've almost bought a C5 many times but never pulled the trigger. I would like an Evo but don't like the image/attention that goes with it. Plus they're kind of pricey still.
_________________________
2001 MR2 Spyder silver needs to go to tracks 1968 Porsche 912 (carbd and shit) 2001 Honda Insight 5-sp stealthy silver DD. 1850 lbs S2K seats and stuff swapped in SOLD AP1 S2000 GPW/red, 1992 Talon TSI AWD (12.9@105), 1984/1986/1999 Mustang 5/5/4.6
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#3620474 - 04/03/09 12:07 PM
Re: I don't drink milk but...
[Re: DanTSiAWD]
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CommonGutterTrash
This user is more useless than a half-baked compost pile.
Post Master Sr
Registered: 09/16/02
Posts: 6437
Loc: Boston MA
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teal talon!
*w00t*
_________________________
Craig R. 2000 9-5 Gary Fisher Wagon 1995 850 T-5R 1996 Galant AIM = gclipse96
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#3620769 - 04/03/09 01:33 PM
Re: I don't drink milk but...
[Re: CommonGutterTrash]
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DanTSiAWD
Poster
Registered: 09/13/08
Posts: 221
Loc: Bay Area, CA
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It's for sale, cheap!
_________________________
2001 MR2 Spyder silver needs to go to tracks 1968 Porsche 912 (carbd and shit) 2001 Honda Insight 5-sp stealthy silver DD. 1850 lbs S2K seats and stuff swapped in SOLD AP1 S2000 GPW/red, 1992 Talon TSI AWD (12.9@105), 1984/1986/1999 Mustang 5/5/4.6
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#3620952 - 04/03/09 02:19 PM
Re: I don't drink milk but...
[Re: DanTSiAWD]
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CommonGutterTrash
This user is more useless than a half-baked compost pile.
Post Master Sr
Registered: 09/16/02
Posts: 6437
Loc: Boston MA
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hah... I have a DSM.
there's one locally... I always chuckle when I drive by it.
it's such a hard color to "take seriously".
but I do love the color.
_________________________
Craig R. 2000 9-5 Gary Fisher Wagon 1995 850 T-5R 1996 Galant AIM = gclipse96
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#3623382 - 04/04/09 03:51 PM
Re: I don't drink milk but...
[Re: vwkaferman]
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AMGSiR
Post Master Sr
Registered: 08/23/04
Posts: 7730
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KERMIT!
You work for sharkwerks??
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#3628095 - 04/06/09 07:05 PM
Re: I don't drink milk but...
[Re: vwkaferman]
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DanTSiAWD
Poster
Registered: 09/13/08
Posts: 221
Loc: Bay Area, CA
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You asshole. You make me realize the hole in my garage is more than enough room to get a project car into, and I need a new project
!!! Yes you definitely do need a new project.
i can't wait to see that car cleaned up... damn
I'll be sure to post up when I do work on it.
 Awesome! Good kill man, I've thrown this idea around as well. Either getting an old 912 or even a 914. Love 'em. Great post with pics, keep 'em coming! James
Thanks James,
Yeah I used to want a 914, too. The only reason I went for the 912 was because the 914s are almost too cheap and I see a lot of them for sale. I figured if I dumped a bunch of time and money into it, I might actually recover some of it with a 911 or 912. But I'll try a 914 some day for sure. My roommate has an ultra clean 914-6, orange with GT widebody flares etc. Maybe I have pics of it here somewhere... hmm
KERMIT!
You work for sharkwerks??
Yep! There's Alex (most people know him) and James (the mad mechanic). I'm the other guy.
_________________________
2001 MR2 Spyder silver needs to go to tracks 1968 Porsche 912 (carbd and shit) 2001 Honda Insight 5-sp stealthy silver DD. 1850 lbs S2K seats and stuff swapped in SOLD AP1 S2000 GPW/red, 1992 Talon TSI AWD (12.9@105), 1984/1986/1999 Mustang 5/5/4.6
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#3630045 - 04/07/09 01:17 PM
Re: I don't drink milk but...
[Re: DanTSiAWD]
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AMGSiR
Post Master Sr
Registered: 08/23/04
Posts: 7730
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Very cool! You guys do come cool stuff. I've got 3 GT700 kits locally from EVO which it looks like you guys have a lot of experience with.
Damn these cars make power.
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#3643816 - 04/12/09 08:53 PM
Re: I don't drink milk but...
[Re: hustler]
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DanTSiAWD
Poster
Registered: 09/13/08
Posts: 221
Loc: Bay Area, CA
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Hey guys I figured I might as well post an update here. Since I was sick for a few days I got behind, but today I had a few hours so I pulled both carburetors from the motor. Those inner nuts were kind of a bitch, mainly because one of the studs was way too long.
Overall though, easy-peasy and I had the carbs out in about a half hour.
I took apart just one today. Both are actually leaking in the same place (the accelerator pump diaphragm was ripped).
Here's my "Carburetor Rebuild Workshop" (sponsored by Brembo and HRE):
Taking it apart into layers, it was clear that it was really nasty inside anyway:
Here's what was causing the gas to leak into the engine bay:
I spent a couple hours with carburetor cleaner and Scotch-brite pads scrubbing and cleaning up the exterior of the main housing, then cleaned all the gasket surfaces, blew everything out, and replaced the float valve. Finally I replaced the torn diaphragm and reassembled everything with new gaskets:
The rebuild kit actually did not include the top gasket, so I will need to cut a couple myself. It just connects the carb to the air cleaner housing. I also did not spend a whole lot of time on the "Redline" air cleaner lid yet that's heavily corroded. I'll either sand it down and paint it, then sand off the stuff that sticks up (making the Redline logo etc. chrome and the rest black) or just polish the whole thing.
_________________________
2001 MR2 Spyder silver needs to go to tracks 1968 Porsche 912 (carbd and shit) 2001 Honda Insight 5-sp stealthy silver DD. 1850 lbs S2K seats and stuff swapped in SOLD AP1 S2000 GPW/red, 1992 Talon TSI AWD (12.9@105), 1984/1986/1999 Mustang 5/5/4.6
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#3644136 - 04/12/09 11:13 PM
Re: I don't drink milk but...
[Re: DanTSiAWD]
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00Formula
00Formula
Unregistered
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I'd try to polish up the whole redline cover first since it's all aluminum.
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#3644190 - 04/12/09 11:37 PM
Re: I don't drink milk but...
[Re: ]
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silentfurymm
Post Master Sr
Registered: 03/03/02
Posts: 7549
Loc: SoCal....again
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So other than the massive amount of surface rust in the floor pan, that looks like a pretty sweet project. I hope its surface rust anyway, otherwise that would suck.
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#3660812 - 04/17/09 10:51 PM
Re: I don't drink milk but...
[Re: silentfurymm]
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DanTSiAWD
Poster
Registered: 09/13/08
Posts: 221
Loc: Bay Area, CA
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I don't have any pictures handy but here's the gist of what's new on the 912...
I finished rebuilding the second carburetor and it looks pretty good, too. I didn't spend a whole lot of time polishing up the air cleaners, but they look decent. I re-installed the carbs after replacing the fuel line that runs behind the fan (this line is notorious for leaking and causing fires on these cars).
The car runs about the same, maybe even a bit harder to start than before, but I haven't tried tuning the carbs yet. However, the fuel leaks are all fixed!
I also replaced the deck lid strut because the lid was falling on my head while working on the car. Now it springs up with authority.
I spent the last couple of days replacing all the lights around the car so I can begin driving it. When I started, 1/4 turn signals worked, 2/4 parking lights worked, 0/2 brake lights worked, 0/2 license plate light lights worked. I replaced all 12 of these bulbs (about $20) which fixed about half of them... but I had to clean every connector and ground with a razor blade/pick/sandpaper to get most of them working. Now I'm happy to say 4/4 turn signals, 4/4 parking lights, 1/2 brake lights, and 2/2 license plate lights work perfect. I haven't traced down that second brake light but the wire looks fine so I'll look into it this weekend (there's one wire that runs from one brake light to the other, through the outside of the car and again through the deck lid area). I also couldn't figure out why the reverse lights don't work, but I'm pretty sure it's the switch. Anyway, the car has *most* lights and I don't feel unsafe driving it now.
Since the driver's seat was installed, I installed the seat belt for it, and because I just added it to my insurance ($9/month!) I took it for a spin around the block. It was pretty fun to drive, so I ran inside and grabbed the digital camera, and shot this video:
http://www.youtube.com/watch?v=AiAbj_UzDNc
Warning: the audio is terrible and an airplane flies over head at the end, but you get the idea.
More to come later.
_________________________
2001 MR2 Spyder silver needs to go to tracks 1968 Porsche 912 (carbd and shit) 2001 Honda Insight 5-sp stealthy silver DD. 1850 lbs S2K seats and stuff swapped in SOLD AP1 S2000 GPW/red, 1992 Talon TSI AWD (12.9@105), 1984/1986/1999 Mustang 5/5/4.6
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#3735105 - 05/14/09 10:48 PM
Re: I don't drink milk but...
[Re: GB]
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DanTSiAWD
Poster
Registered: 09/13/08
Posts: 221
Loc: Bay Area, CA
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We have been busy lately, but I had a little time to work on the 912 which required immediate attention.
First, the turn signals stopped working. They were pretty rough in the first place. They didn't shut off automatically when finishing a turn, and the right signal was becoming hard to engage. Finally last night, right stopped working altogether. Then left this morning. I also broke my driver-side window roller this week, so I couldn't easily roll down my window to perform those cool hand signals.
So I took off the steering wheel and disassembled the column slightly. Luckily it's all easy to move, just requiring a few screws. While I was in there I cleaned everything nice and pretty. I couldn't find anything damaged in the signals, but it was definitely stuck. James suggested contact cleaner, and after a few sprays (and dirty paper towels later) the signal started working. I continued to clean up the little cluster of complex gears and finally sprayed a dry lubricant on when I was finished. Now they work like new!
I reassembled the wheel but somehow lost the horn in the process. I will have to fix that this weekend.
I also mentioned before that the lack of mirrors was making the car pretty dangerous to drive. The car came from the factory with only the driver's side, and I plan to keep it this way. Here's some ugly plastic aftermarket mirrors the previous driver had installed:
They looked tacky and actually were really bad mirrors, constantly moved around etc. Shown also is the stock mirror. But I realized this was from a 66-67 model, so I swapped out for this larger one:
I purchased the small one on Craigslist for $30, the bigger for $45.
One of the most unappealing things about the car was the rear deck lid grille. This piece is notorious for being warped or damaged (look at 68 and 69 911s, 912s and you'll see what I mean). Mine was missing a couple bars and many others were bent (this is after I tried straightening them out):
I popped into Parts Heaven in Hayward and saw this one on a 911E, so I quickly purchased and installed it:
Big improvement eh?
_________________________
2001 MR2 Spyder silver needs to go to tracks 1968 Porsche 912 (carbd and shit) 2001 Honda Insight 5-sp stealthy silver DD. 1850 lbs S2K seats and stuff swapped in SOLD AP1 S2000 GPW/red, 1992 Talon TSI AWD (12.9@105), 1984/1986/1999 Mustang 5/5/4.6
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#3735239 - 05/14/09 11:34 PM
Re: I don't drink milk but...
[Re: DanTSiAWD]
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silentfurymm
Post Master Sr
Registered: 03/03/02
Posts: 7549
Loc: SoCal....again
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Good stuff. What are you going to do about the rust in the floorpan?
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#3735368 - 05/15/09 12:30 AM
Re: I don't drink milk but...
[Re: silentfurymm]
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DanTSiAWD
Poster
Registered: 09/13/08
Posts: 221
Loc: Bay Area, CA
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Good stuff. What are you going to do about the rust in the floorpan?
I'm trying to score some newer galvanized floor pans to replace the rusty section of mine (rather than replace the whole thing). I also have some Eastwood rust converter and encapsulator that I'll get around to one of these weekends.
_________________________
2001 MR2 Spyder silver needs to go to tracks 1968 Porsche 912 (carbd and shit) 2001 Honda Insight 5-sp stealthy silver DD. 1850 lbs S2K seats and stuff swapped in SOLD AP1 S2000 GPW/red, 1992 Talon TSI AWD (12.9@105), 1984/1986/1999 Mustang 5/5/4.6
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#3739413 - 05/16/09 06:12 PM
Re: I don't drink milk but...
[Re: DanTSiAWD]
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SiOfRelief
SiOfRelief
Unregistered
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Nice project
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#3760617 - 05/23/09 07:11 PM
Re: I don't drink milk but...
[Re: ]
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DanTSiAWD
Poster
Registered: 09/13/08
Posts: 221
Loc: Bay Area, CA
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Thanks guys.
Another week down and a couple new additions to the 912. I'm driving it every day now, and the car's loosening up nicely. It's a lot of fun and gets plenty of stares (maybe because it -looks- so old with this paint being flat, beat-up etc.)
The whole time, I've been driving it with the interior gutted to bare metal except the dash and driver's seat. Since all the rust scraping and brushing was now complete, I finally had the time to apply the Eastwood 2-part rust converter.
You take 4 parts of one solution (resembles slimy, thick kool-aid) and mix it with 1 part of the wetting solution (resembles alcohol) and stir. It looks like thick purple paint when you're done mixing. I used a spray can cap for the measuring tool.
I used a tiny foam roller and tray ($3 at Walmart) to apply. I went over every bit of rust and most of the painted stuff too just for good measure, applying a really thick, wet coat. After an hour or so I applied another. Within minutes, the rust begins to turn black.
I did about 1/4 of the interior at a time, and it took ~3 hours to do the whole interior.
The "before" pictures from earlier:
Half-way done:
A couple hours later, the rust was now all completely black, as black as death. No rust dust comes off it, etc.
It's pretty neat stuff because it starts out gooey and sticky, then over time it dries up and it only affects the rust. The areas with some leftover factory paint don't change colors.
It's been days now and the interior finally has no more rust smell. The next step is the Eastwood rust encapsulator, which will coat everything in a rust-sealed paint with a heavy top-coat, then I'll worry about any leftover small holes or areas that need patching, such as the back seat cushion area.
Today I had a few hours at the shop, so I applied the Eastwood Rust Encapsulator (Eastwood Co. - Rust Encapsulator). It's basically paint, but really thick good paint that's meant to prevent/cover rust.
Lesson learned: cheap wal-mart foam rollers don't hold up well to this stuff! I used 6 rollers and 3 trays, and a whole quart of encapsulator on the interior only using two coats on the floor pans (and the rest was coated once).
I spent about an hour on each floor pan just rolling it in thickly, another hour or so on the top decklid area, and maybe an hour under the dash (repainted it all black), quarter panels, sides and pedals. I also re-coated the e-brake handle and shifter base.
It's still got a few hours before it's completely dry, but overall I'm very happy with the results.
Keep in mind there's still going to be carpet, floor mats, seats etc. 
Driver quarter panel interior:
There's also a vinyl cover for this (and seat bottoms, carpet, etc).
Through the dirty back window you can see the deck area (it's covered in a large vinyl pad that I need to clean up still):
The pedals are a nice improvement, but the pic didn't come out so well...
I am going to have the seat adjuster rails sand blasted and powdercoated next. With it being a weekend and Monday a holiday, it looks like I'll have to install/remove the seat once again in a few days. I think I've done that about a dozen times already.
Edited by DanTSiAWD (05/25/09 12:57 AM)
Edit Reason: Added "Before" Pictures
_________________________
2001 MR2 Spyder silver needs to go to tracks 1968 Porsche 912 (carbd and shit) 2001 Honda Insight 5-sp stealthy silver DD. 1850 lbs S2K seats and stuff swapped in SOLD AP1 S2000 GPW/red, 1992 Talon TSI AWD (12.9@105), 1984/1986/1999 Mustang 5/5/4.6
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#3760854 - 05/23/09 10:39 PM
Re: I don't drink milk but...
[Re: DanTSiAWD]
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silentfurymm
Post Master Sr
Registered: 03/03/02
Posts: 7549
Loc: SoCal....again
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Wow, never heard of that stuff. Nice job, that rust would have scared me away, but this project just keeps more awesome.
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#3760989 - 05/24/09 12:15 AM
Re: I don't drink milk but...
[Re: silentfurymm]
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GrizzleHorn
Jr Member
Registered: 01/05/07
Posts: 648
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I love this thread.
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#3762202 - 05/24/09 07:04 PM
Re: I don't drink milk but...
[Re: NOT spotch...]
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DanTSiAWD
Poster
Registered: 09/13/08
Posts: 221
Loc: Bay Area, CA
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Thanks guys
Hey Spotch,
Yes it does work on any metal. If it was exterior I'd probably take additional steps to protect it (like rubberized truck coating stuff) but since it'll be covered in carpet, it's not too important.
_________________________
2001 MR2 Spyder silver needs to go to tracks 1968 Porsche 912 (carbd and shit) 2001 Honda Insight 5-sp stealthy silver DD. 1850 lbs S2K seats and stuff swapped in SOLD AP1 S2000 GPW/red, 1992 Talon TSI AWD (12.9@105), 1984/1986/1999 Mustang 5/5/4.6
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#3762958 - 05/24/09 11:29 PM
Re: I don't drink milk but...
[Re: DanTSiAWD]
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sarge
Sr Member
Registered: 10/11/02
Posts: 1229
Loc: Okinawa, Japan
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That floor pan looks amazing.
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1992 R32 GTR
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#3830281 - 06/17/09 06:10 PM
Re: Dan's Porsche 912 Project
[Re: DanTSiAWD]
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DanTSiAWD
Poster
Registered: 09/13/08
Posts: 221
Loc: Bay Area, CA
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I posted this thread up on a bunch of Porsche forums, and recently finally posted it on the big one (912bbs.org). The replies I got were all different than the other forums.. I don't know why I waited so long to post it there.
Anyway, one of the replies said,Dan
Have you looked under your steering wheel cover? That sure looks like a wood wheel, correct me if I am wrong...
I had not thought too much about the steering wheel, but assumed since it was covered with this ugly $1 wheel wrap that it was probably worn out. I also assumed it was rubber like most of the 912s and older Porsches I see, and from glancing through the wrap when I first bought the car, it looked like the rubber had worn out and was down to the inner metal wire. I assumed it was much worse UNDER the wrap than the wrap itself.
Curiosity got the best of me, so I went outside and removed the wheel wrap. As I began untying the nylon, I felt like an archeologist unveiling some great artifact. I peeled back a little bit and I was shocked: it was indeed wood! As I carefully untied the rest over the next few minutes, I unveiled more and more of the wheel. By the time I removed the whole thing, it was clear that the wheel was not only wood as the guy had suggested, but nearly in perfect shape. The cover preserved it very well over the years! It even has cool grooves for your fingers that I couldn't feel before.
I looked it up and sure enough, a wooden steering wheel was a factory option back in 1968.
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This car is just full of surprises!
before:
Edited by DanTSiAWD (06/17/09 06:18 PM)
_________________________
2001 MR2 Spyder silver needs to go to tracks 1968 Porsche 912 (carbd and shit) 2001 Honda Insight 5-sp stealthy silver DD. 1850 lbs S2K seats and stuff swapped in SOLD AP1 S2000 GPW/red, 1992 Talon TSI AWD (12.9@105), 1984/1986/1999 Mustang 5/5/4.6
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#3830372 - 06/17/09 06:55 PM
Re: Dan's Porsche 912 Project
[Re: DanTSiAWD]
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ElectronVTEC2
Post Master Sr
Registered: 07/10/08
Posts: 5915
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That is awesome man, nice project!!
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2011 Edge (Wife's appliance) EVO IX MR, minor mods 
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#3865649 - 06/30/09 04:25 PM
Re: Dan's Porsche 912 Project
[Re: DanTSiAWD]
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DanTSiAWD
Poster
Registered: 09/13/08
Posts: 221
Loc: Bay Area, CA
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It's been pretty hot here and we were very busy on our new Project Gallery, but I did manage to make a few changes over the last couple of weeks.
The most obvious problem when driving my 912 now was that its tires were very old and cracked. They were so hard, that I'm not sure they were made of rubber anymore. I think they were more like biscuits. I would lock them up driving into my driveway even. There was simply no traction.
I ordered five Good Year Eagle GT tires. I ordered the 5th for a spare. The tires were 195/60/15s, about the biggest you want to run on stock wheels from my understanding. I did a bit of research and read that these tires offer good performance for the price and I liked the tread pattern versus the other brands such as Michelin or Yokohama.
I also reached a point in the project where I would take a turn -- and I know some people won't like this. I looked at 911s and 912s for months to decide how I'd want mine to look, and something about the Fuchs wasn't doing it for me. Maybe it's because they're common, or maybe I just don't think they "fit" on the car, especially with this color. I am not a big fan of chrome/polish, so I couldn't do the hubcap. I took a slightly different direction.
I bought 5 steel wheels. I had no spare before, so I figured I may as well have a matching one. These are actually spares from the later 911s, so usually they're in pretty good shape. They're also cheap - the cost of these wheels plus tires is about what my Fuchs will sell for, so I'll basically trade my Fuchs without tires for steel wheels with brand new tires and gain a spare. They are quite a bit heavier (6.5 lbs per corner!), but since I intend to make this car a cruiser, I don't mind the extra rolling mass for now.
Most of them looked decent, but had OEM stickers on them:
I removed the sticker with Brake cleaner first, and cleaned and degreased all the wheels.
The roughest wheel had some surface rust:
The stack of the tiny wheels next to Cayenne TT tires (:lol:):
After brake parts cleaner and wire brushing...
Here's the paint I opted to use. It's the Rustoleum "Hammered Finish" silver. This is the same durable paint I used on my homemade gaming seat.
I love this paint because of the finish it leaves, but it's also very strong for "cheap" spray paint.
It started raining minutes after my first ultra-light coat was applied to each wheel, so I had to wait 2-days to apply more paint.
Picking up where I left off, the final coats turned out exactly how I wanted them. I applied 2 very thin coats and 2 heavier coats.
The biggest problem was that they're now -too- clean and shiny, and the rest of the car isn't. As I am putting on some miles they are getting brake dust and road grime, completing the look I was going for.
Most recent pictures with the steelies, now with steel blackish lugnuts instead of chrome/aluminum caps. I still need to paint or clean up the centers though, which I'll do soon when I work on the brakes:
The car's running awesome. It seemed pretty fast on the way to work today with nice cool weather. Starts right up and idles fine, and now with these tires I've really been chucking it around some corners!
_________________________
2001 MR2 Spyder silver needs to go to tracks 1968 Porsche 912 (carbd and shit) 2001 Honda Insight 5-sp stealthy silver DD. 1850 lbs S2K seats and stuff swapped in SOLD AP1 S2000 GPW/red, 1992 Talon TSI AWD (12.9@105), 1984/1986/1999 Mustang 5/5/4.6
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#3866250 - 06/30/09 08:50 PM
Re: Dan's Porsche 912 Project
[Re: YodaGTS]
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SiOfRelief
SiOfRelief
Unregistered
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Looking great
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#3866272 - 06/30/09 08:57 PM
Re: Dan's Porsche 912 Project
[Re: ]
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madmatt
Post Master Supreme
Registered: 09/17/02
Posts: 24697
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To be honest, I actually like steel wheels, so I approve of the change
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#3866476 - 06/30/09 10:30 PM
Re: Dan's Porsche 912 Project
[Re: NOHC]
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scootergeek
Post Master Supreme
Registered: 07/24/00
Posts: 46248
Loc: East of St. Louis
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This is the coolest project car in SvA
Fixed (the Pantera is a complete runner, so it's not really a project is it?)
cheers,
scott
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Still pissy after all these years...
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#3992172 - 08/16/09 10:09 PM
Re: Dan's Porsche 912 Project
[Re: pumpkin escobar]
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DanTSiAWD
Poster
Registered: 09/13/08
Posts: 221
Loc: Bay Area, CA
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I had a longer post written but I lost it by accident, so here's take 2.
One thing that bothered me about the car was its pretty new white license plate. It just didn't match.
As of July 1, 2009, Californians can put the original color of plates back on the car if they have an unregistered front and rear set, and pay a small fee. My friend just happened to have a set, and he gave them to me for my car.
I found a more suitable license plate frame on Ebay for $35. It looked too busy for the back so I put it on the front.
I used my cheap art kit's paints to carefully retouch the plate. I wanted it to look old still, but the numbers and black were a little rusty and it was a mess.
Finally, I put a $5 chrome frame on the rear plate:
The brakes were starting to make lots of noise, and one side had been pulling for weeks. I bought replacement calipers with pads for $50. Removing old calipers:
The rears seemed fine. Fronts were well ready.
I like how you can change the pads in seconds if you want to. But since I was replacing the calipers, too it's a bit bigger job.
This is not how a brake pad is supposed to look:
The new calipers were much nicer and cleaner. The rotor had a little wear, but they were pretty good still and we saw no need to replace.
Then we bled the fronts, and threw the wheels back on.
We left the shop and agreed to meet about 15 miles south at a restaurant for lunch. Since my 912 has one seat still, I drove solo. I was scared of the freeway, since I had only taken the car on it once and that was over a month ago. It had been sitting since then with a few new parts. But I figured it'd be okay. I merged onto the freeway at 70 and about 2 miles later the car started losing speed, it seemed really down on power. I noticed it was getting worse, so I pulled over.
A highway patrol officer was out back before I was out of the car. Amazing. He was really young and asked if everything was okay, to which I replied and told him my friend was coming. He didn't want to stick around so he told me to sit in the seat with the lapbelt on until my friend arrived.
A couple minutes later after baking in 80+ without a moving car or AC, I popped the back. I couldn't find anything immediately wrong. The fuel looked a little low in the filter, but it was clean. Still, the low fuel seemed to be an indication that somewhere from the gas tank to the fuel pump, we had a problem. Maybe the fuel pump itself, but it's hard to say this soon.
The car wouldn't idle very well, but I was able to bring it back to the shop without trouble. I think some loose crap from the tank has dislodged finally and I should probably replace both filters from just a few months ago, as sediment made its way from the tank. I guess I should really clean that up next.
_________________________
2001 MR2 Spyder silver needs to go to tracks 1968 Porsche 912 (carbd and shit) 2001 Honda Insight 5-sp stealthy silver DD. 1850 lbs S2K seats and stuff swapped in SOLD AP1 S2000 GPW/red, 1992 Talon TSI AWD (12.9@105), 1984/1986/1999 Mustang 5/5/4.6
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#3993431 - 08/17/09 12:25 PM
Re: Dan's Porsche 912 Project
[Re: Benelliwang]
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DanTSiAWD
Poster
Registered: 09/13/08
Posts: 221
Loc: Bay Area, CA
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I hate your milks, wish I have your milks lol jealousy
Both insight and 912 are uber cool
Thanks mate! Really cool to read that considering the cars in your sig.
I was a DSM / Mustang guy in the past. These are quite a change from the old stuff.
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2001 MR2 Spyder silver needs to go to tracks 1968 Porsche 912 (carbd and shit) 2001 Honda Insight 5-sp stealthy silver DD. 1850 lbs S2K seats and stuff swapped in SOLD AP1 S2000 GPW/red, 1992 Talon TSI AWD (12.9@105), 1984/1986/1999 Mustang 5/5/4.6
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#3993450 - 08/17/09 12:28 PM
Re: Dan's Porsche 912 Project
[Re: hustler]
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DanTSiAWD
Poster
Registered: 09/13/08
Posts: 221
Loc: Bay Area, CA
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Wewt! Awesome updates man, the floor pan turned out awesome. Definitely checking in to this thread often.
Thanks! I'll be sure to post more as I complete work. I'll be out of the US for a couple weeks here, but I have boxes of parts for this thing piling up now.
Yeah this is very cool to follow, and enjoy following your posts and updates. I know it takes work to essentially blog this on the net with pictures. I will tell you though that I found some surface rust on the floorpans as well and found this thread incredibly useful. I will try the exact same method. Old cars like to hide their problems, but you just have to find them out. Keep it up and look forward to the next update!
Thanks much for the reply. Yes it is a bit of work, but I've done similar stuff online since the late 90s so I now have the process down to a science. It's pretty fast at this point. I should try to take better photos, but snapping with my phone then emailing when I get home is so easy.
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2001 MR2 Spyder silver needs to go to tracks 1968 Porsche 912 (carbd and shit) 2001 Honda Insight 5-sp stealthy silver DD. 1850 lbs S2K seats and stuff swapped in SOLD AP1 S2000 GPW/red, 1992 Talon TSI AWD (12.9@105), 1984/1986/1999 Mustang 5/5/4.6
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#3999089 - 08/18/09 11:46 PM
Re: Dan's Porsche 912 Project
[Re: _vti]
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SiOfRelief
SiOfRelief
Unregistered
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Reminds me of Edd China in Wheeler Dealer
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#4474620 - 01/30/10 03:15 PM
Re: Dan's Porsche 912 Project
[Re: ]
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SiOfRelief
SiOfRelief
Unregistered
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I just received the latest issue of Excellence magazine - were you involed in the article on the two modified Porsches? The green "kermit" car looks great.
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#4478862 - 02/01/10 01:34 PM
Re: Dan's Porsche 912 Project
[Re: ]
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DanTSiAWD
Poster
Registered: 09/13/08
Posts: 221
Loc: Bay Area, CA
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I just received the latest issue of Excellence magazine - were you involed in the article on the two modified Porsches? The green "kermit" car looks great.
Yessir! All the rolling photos were shot from my Honda Insight.
We drove some ~400 miles that day through some of the best roads in northern CA. My little hybrid got one hell of a workout. We recently went back and I drove the green car the whole time (another 300 miles or so). It's pretty intense driving that RR/500 HP car on those roads. I was shaking and sweating for hours afterward. 
_________________________
2001 MR2 Spyder silver needs to go to tracks 1968 Porsche 912 (carbd and shit) 2001 Honda Insight 5-sp stealthy silver DD. 1850 lbs S2K seats and stuff swapped in SOLD AP1 S2000 GPW/red, 1992 Talon TSI AWD (12.9@105), 1984/1986/1999 Mustang 5/5/4.6
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#4480643 - 02/02/10 02:20 AM
Re: Dan's Porsche 912 Project
[Re: ForeheadSMASH]
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DanTSiAWD
Poster
Registered: 09/13/08
Posts: 221
Loc: Bay Area, CA
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It was raining here for literally like a month on and off, plus a few other things delayed me from posting updates. The car also broke down at some point.
When I bought it, the original fuel pump was seized up and had no pressure. I installed a Facet electric pump. It worked, but the car ran poorly and eventually it left me stranded (trying to on the freeway, the car leaned out). So I ordered a rebuild kit for the OEM mechanical pump (replacing the pump is $350 or something). I rebuilt the fuel pump and the car ran better than it ever did with the electric pump. It actually felt fast in some bizarre way. And it revved great.
Then one day I was coming home from harbor freight (a "long" drive for the 912 at this point is 10 miles) and it died again. I had to pull into a parking lot and try to fix it there. It was the fuel pump that I had rebuilt a few weeks earlier. My roommate brought the crappy electric pump and it was enough to get the car home. I took apart the fuel pump and the rivet that holds the plunger to the diaphragm broke. I imagine the OEM rivet was fine 40 years later. So we rigged up a solution and the car's back on the road. Then it began raining.
_________________________
2001 MR2 Spyder silver needs to go to tracks 1968 Porsche 912 (carbd and shit) 2001 Honda Insight 5-sp stealthy silver DD. 1850 lbs S2K seats and stuff swapped in SOLD AP1 S2000 GPW/red, 1992 Talon TSI AWD (12.9@105), 1984/1986/1999 Mustang 5/5/4.6
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#4484747 - 02/03/10 12:31 PM
Re: Dan's Porsche 912 Project
[Re: ]
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DanTSiAWD
Poster
Registered: 09/13/08
Posts: 221
Loc: Bay Area, CA
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I'm in northern CA. I started the detail process a few weeks ago. Just clay bar and wool pad correction first. I'll have pictures eventually showing everything. There are lots of dents, dings, and bits of paint missing here and there, poor touch up etc. The roof looks awesome except for its waveyness. But the paint does shine nicely. Gotta love an old German base coat w/o clear for that type of restoration.
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2001 MR2 Spyder silver needs to go to tracks 1968 Porsche 912 (carbd and shit) 2001 Honda Insight 5-sp stealthy silver DD. 1850 lbs S2K seats and stuff swapped in SOLD AP1 S2000 GPW/red, 1992 Talon TSI AWD (12.9@105), 1984/1986/1999 Mustang 5/5/4.6
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#4787899 - 06/01/10 06:05 PM
Re: Dan's Porsche 912 Project
[Re: ]
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DanTSiAWD
Poster
Registered: 09/13/08
Posts: 221
Loc: Bay Area, CA
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#4788434 - 06/01/10 08:59 PM
Re: Dan's Porsche 912 Project
[Re: Anastasia Beaverhausen]
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madmatt
Post Master Supreme
Registered: 09/17/02
Posts: 24697
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WOW that thing looks incredible man! Nothing like a little elbow grease
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#5904789 - 11/02/11 11:07 PM
Re: Dan's Porsche 912 Project
[Re: madmatt]
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Panda Express
Post Master Supreme
Registered: 12/27/00
Posts: 44172
Loc: DFW, Texas
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Back from the dead, any updates?
_________________________
#TeamLH aka old ladies at IKEA walk up to me and ask "Do you work for Mercedes Benz?" #Hamfosi My FlickR y0!
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#6006705 - 12/20/11 02:00 AM
Re: Dan's Porsche 912 Project
[Re: SiZ]
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DanTSiAWD
Poster
Registered: 09/13/08
Posts: 221
Loc: Bay Area, CA
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Okay it's been quite a while since I updated this. Other than an oil change, I also replaced the brake master cylinder failure and now I need to replace a brake line, figuring I'll do a few. I washed/clayed/polished/sanded and polished just for fun on the paint. I stripped and resprayed the hood, bought some high-back (80s seats, $300 for nice black leather pretty lightweight etc). I realized my Rennline throttle plate wasn't allowing the throttle to open all the way. And what else... it's sitting in my garage at the moment and it's too cold to even think of going out there. I'm going to let it get dirty and oxidize but wanted to fix a couple things. I don't want to paint it, just because I know when I sell it it'll never be good enough for who buys it next. Plus I think it looks great.
I replaced the trunk seal and one of the front glass seals. But I didn't reassemble the door skin and now that front window doesn't close as well.
But it finally has a nice seal! I also wish to fix the window roller uppers but it's a nasty contraption in there. I'm a little scared to bother.
After I get back from seeing my family at Xmas I'm having an upholstery guy install my headliner while my windows will be out (to finally replace the seals) so I can install the rest of the interior.
So I should probably fix the brakes around that time since it's driving with 3 calipers at the moment. I'm considering selling the car, but I want to fix some more stuff first. The worst thing about it since day 1 has been the seats. Really looking forward to having those in.
_________________________
2001 MR2 Spyder silver needs to go to tracks 1968 Porsche 912 (carbd and shit) 2001 Honda Insight 5-sp stealthy silver DD. 1850 lbs S2K seats and stuff swapped in SOLD AP1 S2000 GPW/red, 1992 Talon TSI AWD (12.9@105), 1984/1986/1999 Mustang 5/5/4.6
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#6006719 - 12/20/11 02:38 AM
Re: Dan's Porsche 912 Project
[Re: DanTSiAWD]
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SiOfRelief
SiOfRelief
Unregistered
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What do you plan on selling it for price wise?
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#6015486 - 12/24/11 02:15 AM
Re: Dan's Porsche 912 Project
[Re: ]
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Stig
Post Master Sr
Registered: 07/19/10
Posts: 3252
Loc: NoVa
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Great thread. Saving a car from the junkyard is a great feeling.
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Formerly RiceEater T/A  Porsche Cayman S - Maserati GT - Saab 9000t 400whp forever project car - Nissan Titan
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