Battery box done

Finish the battery box. Etch primed follow by seam sealer and finished the outside with rubberized coating and the inside the same in gray. 

Cleaning and painting parts

TT crossmember refurbishment;

Wired it down, cleaned it with Eastwood Fast Edge, sprayed it with Eastwoods rust encapsulator, sanded and sprayed it with SEM black etch primer....like here. Next I'm going to paint it with Duplicolor DA1603 semi-gloss black acrylic enamel. 

Porsche 928 honorable mentioned in Porsche Magazine

Battery box rust fix

I've never metal form but I'm doing it;

The ugliest welds you'll ever see. I'm going to bring them down and continue to stitch....you'll see!

Battery tray

Cleaning battery tray to treat for rust. Didn't want to weld next to the gas tank but I'm going to have to...

PSD flex line

New line 

Re-tapping

Purchased a kit from Belmetrics.com to repair the broken speed sensor bolt. Driller, re-tapped and installed an sleeve/insert. 

Cleaning time

Nothing over the top...degreaser and pressure water!

PSD

Cleaned and installed the slave cylinder on the transmission. Seemed to be working alright! No binding, sliding in and out easily with what feels like spring like pressure. 

While disconnecting the line from the cylinder the line got twisted and snapped. I need to order a new line and probably the rubber line that comes from the body to the pilot pressure valve. I'll reuse the same valve...all is dirty but we'll see. 

New transmission mounts

Got new transmission mounts.  If I'm here now might as well refresh as much is I can. Check out the difference between the old vs the new mounts:

Speed sensor

Finally got around and drilled thru the center of the speed sensor and very patiently tapped the edges in with a very thin chisel. After an hour I was able to extract what was left of the sensor without dropping debri into the hub. Then cleaned the hole out with my dremel tool. 

Now I have to drill out the bolt and retap it, or re-sleeve it.

My garage

Torque Tube

Got the TT off and it's working beautifully. It must have been rebuilt at some point not too long ago cause it's been powder coated....I don't think they come from factory powder coated. Considering its got a Constantine Clamp! 

Getting ready to install the new transmission. Using my engine hoist to move them around...they're super heavy!

The old:

The less old:

Both transmission side by side:

Need to install this device for the PSD in the new transmission:

New transmission mounts....look at the difference:

Installed:

 

Finally out!

Transmission and TT out!!!!

Cant get the TT off

All four bolts off, softened the Constantine clamp bolts, but I cannot slide the shaft out.

How to disconnect the PSD

Got to research this; need to disconnect the PSD lines to the rear diffential...from which location. I know the system is under high pressure...how do I relive it?

Broken speed sensor

After a week of lubrication and lots of tapping and pulling and lubrication and tapping and pulling this is what I got!  Broken speed sensor....patience! Got to think this thru!!  I guess I could drill thru the middle of the sensor without going all the way thru and tap the edges in separating the sensor wall from the hub. 

HF transmission jack

I had to bite the bullit and purchased a HF transmission jack!