Time to restore my 356 notchback

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David Aronson
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Re: Time to restore my 356 notchback

#61 Post by David Aronson »

More panels fabricated and applied.
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61 Karmann Notchback 200831
67 Karman 912 461567
74 911 Targa (3.0 SC motor)
83 911SC (Concours award winner, still)
95 993
09 Carrera S
69 Triumph TR6, 2004 BMW K1200GT, 2012 R1200RT, 2013 MOTO GUZI V7 RACER
64 VW coupe
Vacaville Ca.

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David Aronson
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Re: Time to restore my 356 notchback

#62 Post by David Aronson »

And I was finished with this part of the sound proofing. Now on to suspension and tunnel installation. All those holes in the front engine compartment bulkhead. What went there?
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What goes where?
What goes where?
20181202_122431.jpg (194.8 KiB) Viewed 4003 times
61 Karmann Notchback 200831
67 Karman 912 461567
74 911 Targa (3.0 SC motor)
83 911SC (Concours award winner, still)
95 993
09 Carrera S
69 Triumph TR6, 2004 BMW K1200GT, 2012 R1200RT, 2013 MOTO GUZI V7 RACER
64 VW coupe
Vacaville Ca.

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David Jones
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Tag: I wish I knew as much as I think I know.
Location: Kentucky

Re: Time to restore my 356 notchback

#63 Post by David Jones »

I have never had the patience to restore a car to the level you are doing David so you have my utmost respect. I do have a question though. From my experience I have been very reluctant to take a freshly painted and restored car out on the roads after completing the work. Are you going to drive it or just show it? Just this last weekend when driving an 80 mile tour with the local PCA club I had a lot of folks commenting both ways on whether or not I should be driving my 59 coupe at speed on the Kentucky backroads, keeping up with the GT3 in front except for the straight bits. I did mention to him that while he was driving his car using some of his performance some of the time, I was using most of my performance most of the time which I feel is more fun. I also noticed that when he put half a wheel off the edge of the road in places he still had more tread on the tarmac than I did.
If I had known I would live this long I would have pushed the envelope a little harder.
Cymru am byth
David Jones #9715

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David Aronson
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Re: Time to restore my 356 notchback

#64 Post by David Aronson »

the key came out but I was surprised that the bearing and the large tube comes with the arm.
the key came out but I was surprised that the bearing and the large tube comes with the arm.
20190118_115230.jpg (184.67 KiB) Viewed 4002 times
First , the seals on the torsion arms needed to be replaced.  Removing the key was no problem.
First , the seals on the torsion arms needed to be replaced. Removing the key was no problem.
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the setting, with 10 shims on the top and bottom, is measured with a micrometer.  Minus the 10mm of the tool.
the setting, with 10 shims on the top and bottom, is measured with a micrometer. Minus the 10mm of the tool.
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I replaced the king pin and wrist pins. The king pins required heat and an air chisel gun. Otherwise, with the aid of the correct reamers (Thanks Ted Blake), the process took one morning.
Now, using the correct VW tool to set up the alignment, the assembly of the front end went smoothly. New tie rod ends and everything powder-coated, looks good.
61 Karmann Notchback 200831
67 Karman 912 461567
74 911 Targa (3.0 SC motor)
83 911SC (Concours award winner, still)
95 993
09 Carrera S
69 Triumph TR6, 2004 BMW K1200GT, 2012 R1200RT, 2013 MOTO GUZI V7 RACER
64 VW coupe
Vacaville Ca.

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David Aronson
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Re: Time to restore my 356 notchback

#65 Post by David Aronson »

David Jones wrote: Mon Mar 25, 2019 2:51 pm I have never had the patience to restore a car to the level you are doing David so you have my utmost respect. I do have a question though. From my experience I have been very reluctant to take a freshly painted and restored car out on the roads after completing the work. Are you going to drive it or just show it? Just this last weekend when driving an 80 mile tour with the local PCA club I had a lot of folks commenting both ways on whether or not I should be driving my 59 coupe at speed on the Kentucky backroads, keeping up with the GT3 in front except for the straight bits. I did mention to him that while he was driving his car using some of his performance some of the time, I was using most of my performance most of the time which I feel is more fun. I also noticed that when he put half a wheel off the edge of the road in places he still had more tread on the tarmac than I did.
Hi David, I originally planned to restore to a driver level. As the project matured, I decided to restore to conours. We will show it for two years and then drive it. I have several spare engines to install so the matching motor can be saved. I too enjoy driving my cars. We had to cancel a tour last week due to weather. I do not like putting them through unnecessary stress and dirt though. Looking to restore an A car next. My 911SC is a show car, winning in preservation class. I drive it all the time. For each hour on the road I spend two on the rack, cleaning. I bet you know all about that. Happy driving!
61 Karmann Notchback 200831
67 Karman 912 461567
74 911 Targa (3.0 SC motor)
83 911SC (Concours award winner, still)
95 993
09 Carrera S
69 Triumph TR6, 2004 BMW K1200GT, 2012 R1200RT, 2013 MOTO GUZI V7 RACER
64 VW coupe
Vacaville Ca.

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David Aronson
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Re: Time to restore my 356 notchback

#66 Post by David Aronson »

Installed all components in tunnel. Parking brake cables, manual accelorator cable, clutch cable. The shifting mechanism will be done after I install the soundproofing on the floors.
Attachments
Forward look at all the materials that occupy the forward tunnel area
Forward look at all the materials that occupy the forward tunnel area
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fuel line with correct rubber seal at engine firewall bulkhead.  notice new wiring harness protected with heavy rubber casing.
fuel line with correct rubber seal at engine firewall bulkhead. notice new wiring harness protected with heavy rubber casing.
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new fuel lines was installed with correct rubber bumpers
new fuel lines was installed with correct rubber bumpers
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heater control cables will be attached to the shifter complex later
heater control cables will be attached to the shifter complex later
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The emergency brake coupling.  you can see the accelerator rod has yet to be connected.  I used aviation primer where a surface needed protection.
The emergency brake coupling. you can see the accelerator rod has yet to be connected. I used aviation primer where a surface needed protection.
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61 Karmann Notchback 200831
67 Karman 912 461567
74 911 Targa (3.0 SC motor)
83 911SC (Concours award winner, still)
95 993
09 Carrera S
69 Triumph TR6, 2004 BMW K1200GT, 2012 R1200RT, 2013 MOTO GUZI V7 RACER
64 VW coupe
Vacaville Ca.

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David Aronson
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Joined: Mon Nov 24, 2014 12:58 pm
Location: Vacaville, Ca
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Re: Time to restore my 356 notchback

#67 Post by David Aronson »

Next, the anterior suspension was finished. New tie rod ends on powder coated rods. Rebuilt spindles and powder coated backing plates. Note that I used aviation type safety wiring instead of one heavy wire. As an aircraft builder with the equipment, I figured I would use that method.
Attachments
Aviation safety wiring.  One area that concourse restoration adherence was not followed.
Aviation safety wiring. One area that concourse restoration adherence was not followed.
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20190327_113907.jpg
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powder coating on all surfaces.  Easier to clean and resists scratching
powder coating on all surfaces. Easier to clean and resists scratching
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20190327_114016.jpg
20190327_114016.jpg (196.12 KiB) Viewed 3952 times
61 Karmann Notchback 200831
67 Karman 912 461567
74 911 Targa (3.0 SC motor)
83 911SC (Concours award winner, still)
95 993
09 Carrera S
69 Triumph TR6, 2004 BMW K1200GT, 2012 R1200RT, 2013 MOTO GUZI V7 RACER
64 VW coupe
Vacaville Ca.

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David Aronson
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Joined: Mon Nov 24, 2014 12:58 pm
Location: Vacaville, Ca
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Re: Time to restore my 356 notchback

#68 Post by David Aronson »

getting ready for the match up of the tranny and car once again.
getting ready for the match up of the tranny and car once again.
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I have this great lift.  I work on all aircooled, rear engine cars.  356, 912, 911s and VWs.  This lift makes it sooooo much easier for one person to control the balance.  I remember when I did this with a floor jack and jack stands.  I got old and that was no fun.  I still can not do the switch out as fast as I could back in the 70s......
I have this great lift. I work on all aircooled, rear engine cars. 356, 912, 911s and VWs. This lift makes it sooooo much easier for one person to control the balance. I remember when I did this with a floor jack and jack stands. I got old and that was no fun. I still can not do the switch out as fast as I could back in the 70s......
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Almost there
Almost there
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One less part laying around.  I hope it stays put for a while.
One less part laying around. I hope it stays put for a while.
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Brakes and steering column installation next. The brakes were rebuilt by Capital Clutch and Brake in West Sacramento. Drums were cleaned, inspected, re-surfaced. Old brake shoes were rebonded and each drum/shoe axel was match arched for better braking efficiency. The total for six seperate drums/brakes (two extra) was 375 bucks. Not bad. New hardware was used, new brake cylinders from Stoddard, and all new brake lines. To make this more concise, I will include the installation of the transmission at this time as well. Transmission was rebuilt by Ron at San Mateo trans-axles. He powder coated the back plates, wt all the tolerances. I made the mistake of filling the tranny with fluid without putting the drums back on. Subsequently, I had a puddle of smelly oil on my garage floor the next morning.
61 Karmann Notchback 200831
67 Karman 912 461567
74 911 Targa (3.0 SC motor)
83 911SC (Concours award winner, still)
95 993
09 Carrera S
69 Triumph TR6, 2004 BMW K1200GT, 2012 R1200RT, 2013 MOTO GUZI V7 RACER
64 VW coupe
Vacaville Ca.

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David Aronson
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Re: Time to restore my 356 notchback

#69 Post by David Aronson »

Brakes anyone?
Attachments
Left front brake installed
Left front brake installed
20190317_144645.jpg (206.28 KiB) Viewed 3949 times
Right front brake installed
Right front brake installed
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A closer look of the use of a left hand e-brake rod on the right side.
A closer look of the use of a left hand e-brake rod on the right side.
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Right Rear.  You may see that the e-brake cast rod is upside down.  I only had two left side parts.  I see no reason to wait and source on as no conflict is seen.
Right Rear. You may see that the e-brake cast rod is upside down. I only had two left side parts. I see no reason to wait and source on as no conflict is seen.
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Left rear.
Left rear.
20190322_145922.jpg (193.08 KiB) Viewed 3949 times
61 Karmann Notchback 200831
67 Karman 912 461567
74 911 Targa (3.0 SC motor)
83 911SC (Concours award winner, still)
95 993
09 Carrera S
69 Triumph TR6, 2004 BMW K1200GT, 2012 R1200RT, 2013 MOTO GUZI V7 RACER
64 VW coupe
Vacaville Ca.

User avatar
David Aronson
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Posts: 315
Joined: Mon Nov 24, 2014 12:58 pm
Location: Vacaville, Ca
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Re: Time to restore my 356 notchback

#70 Post by David Aronson »

Steering box and column installed
Attachments
from other side
from other side
20190327_114036.jpg (177.01 KiB) Viewed 3949 times
another view
another view
20190327_105032.jpg (189.29 KiB) Viewed 3949 times
Installation of ZF box, brake master cylinder and all connections
Installation of ZF box, brake master cylinder and all connections
20190327_105209.jpg (220.5 KiB) Viewed 3949 times
61 Karmann Notchback 200831
67 Karman 912 461567
74 911 Targa (3.0 SC motor)
83 911SC (Concours award winner, still)
95 993
09 Carrera S
69 Triumph TR6, 2004 BMW K1200GT, 2012 R1200RT, 2013 MOTO GUZI V7 RACER
64 VW coupe
Vacaville Ca.

User avatar
David Aronson
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Posts: 315
Joined: Mon Nov 24, 2014 12:58 pm
Location: Vacaville, Ca
Contact:

Re: Time to restore my 356 notchback

#71 Post by David Aronson »

New wheel bearings and races and some pictures before the car is put back on it's own wheels and tires. more later
Attachments
ready for wheels/tires at last
ready for wheels/tires at last
20190325_120651.jpg (207.25 KiB) Viewed 3949 times
wiring to starter
wiring to starter
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rear brake setup, right rear
rear brake setup, right rear
20190325_120619.jpg (165.37 KiB) Viewed 3949 times
new starter
new starter
20190325_120629.jpg (185.27 KiB) Viewed 3949 times
Kroll oil to help loosen the old races, a punch and new races and bearings with seals.
Kroll oil to help loosen the old races, a punch and new races and bearings with seals.
20190322_101046.jpg (207.51 KiB) Viewed 3949 times
Last edited by David Aronson on Thu Mar 28, 2019 6:57 pm, edited 1 time in total.
61 Karmann Notchback 200831
67 Karman 912 461567
74 911 Targa (3.0 SC motor)
83 911SC (Concours award winner, still)
95 993
09 Carrera S
69 Triumph TR6, 2004 BMW K1200GT, 2012 R1200RT, 2013 MOTO GUZI V7 RACER
64 VW coupe
Vacaville Ca.

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Ronald Sieber
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Location: Hillsborough, NC
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Re: Time to restore my 356 notchback

#72 Post by Ronald Sieber »

David:
Great pics! You are doing great work there.

I have to do some work under my car and do not have a four-post lift in my garage due to height limitations. I was wondering if your scissors lift would be a good option for under-car work? If you have had good experience with yours, would you mind naming the brand and commenting on where you placed it to lift the body? It's not quite clear to me from the photos that you have posted.

Thanks,
=rds

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David Aronson
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Re: Time to restore my 356 notchback

#73 Post by David Aronson »

The brand is BendPak. It is available from www.bestbuyautoequipment.com. It is amazing what you can do with ease. You may need to have your garage door opener replaced with a direct drive side-drive unit. Otherwise you will not be able to take advantage of the maximum lift. I included the modifications I made for lifting the 356. Simple to make. Hope that helps. The front lift was fabricated from two angle iron pieced welted together then to a piece of pipe. The rear, 1/2 pipe welded to a piece of pipe. The perch on the torsion tube is ideal.
Attachments
Rear lift support
Rear lift support
20190328_145807.jpg (166.14 KiB) Viewed 3930 times
front lift area
front lift area
20190328_145757.jpg (166.99 KiB) Viewed 3930 times
Bend Pack.  Heavy duty lift.  weighs 1100lbs
Bend Pack. Heavy duty lift. weighs 1100lbs
20190328_145748.jpg (196.68 KiB) Viewed 3930 times
Lift at max
Lift at max
20190328_145816.jpg (204.75 KiB) Viewed 3930 times
61 Karmann Notchback 200831
67 Karman 912 461567
74 911 Targa (3.0 SC motor)
83 911SC (Concours award winner, still)
95 993
09 Carrera S
69 Triumph TR6, 2004 BMW K1200GT, 2012 R1200RT, 2013 MOTO GUZI V7 RACER
64 VW coupe
Vacaville Ca.

User avatar
David Aronson
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Posts: 315
Joined: Mon Nov 24, 2014 12:58 pm
Location: Vacaville, Ca
Contact:

Re: Time to restore my 356 notchback

#74 Post by David Aronson »

Raining today, again. California is getting the rain it needs. More than it can handle though. Today I will install the newly rebuilt guages. These were finished by Palo Alto Speedo.
I have been waiting for a few part so will get to this. The Steering column was powder coated. Turn signal switch had to be removed. I used the opportunity to clean it and refresh some solder joints. It came out very nice. Now to refit the column, and attach the rubber steering damper. Pictures of it are above this entry. Pictures later.
61 Karmann Notchback 200831
67 Karman 912 461567
74 911 Targa (3.0 SC motor)
83 911SC (Concours award winner, still)
95 993
09 Carrera S
69 Triumph TR6, 2004 BMW K1200GT, 2012 R1200RT, 2013 MOTO GUZI V7 RACER
64 VW coupe
Vacaville Ca.

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Kip Colvey
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Joined: Tue Nov 09, 2010 10:31 pm
Location: New Zealand

Re: Time to restore my 356 notchback

#75 Post by Kip Colvey »

Hi David,

Double check your front brake shoes. Pictures in the factory workshop manual shows the shoes installed differently. Nice work on your Notchback.

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