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Remaining items and where they will be fixed

The stereo (!) needs to have the accessory lead hooked up because it keeps losing the preset stations.

And the aerial needs to be connected properly. Reception is poor at the moment.

The wiper needs to be replaced and it's difficult to find a unit that fits.

The fuel float is stuck, so I need to remove the tank and remove the pump and see what's going on, as that's where the float is. Doing this will probably induce a fuel leak, so I am reluctant and just keep careful watch on my odometer. But I would like a working fuel gauge. If I do this, I would like to replace the tank with a bigger capacity one so I can have a better cruising range.

And this would be the time to spray sound-deadening foam in the fuel tank area.

The heat shield vibrates/resonates too much. I need to fix the fucking thing.

I need to plumb a couple of hoses together and hook them up to a charcoal canister in the engine compartment.

Extras:

1) I want to make the rear clamshell hinged so I can access the rear storage compartment without having to unbolt the whole clamshell.

2) I want to put in a plexiglass window in the rear clamshell so the rearview mirror isn't quite so useless as it is right now.

3) I want to make the roof removable, so I have to figure out some quick-release but secure fastening mechanism.

Home	Garage	Sean (friend)	Questions for Geary
Turn signals (still!) don’t work Tighten mirrors Paint touchup Adjust passenger door Add more soundproofing	Put in hub spacers Wheel alignment Put in transparent access hatch in rear clamshell (for rear visibility and for access to storage compartment	Bleed brakes	Turn Signal troubleshooting Spare plug under dash? For alarm. Rear brake pad swept area Brake lights don’t work unless I brake hard Adjusted switch Emergency brake light in dash always on Fixed leaking master cylinder and topped up fluid and bled brakes Steering adjustment Cannot be adjusted without replacing steering rack (to be investigated at a later point)

Done

June 21st, 2002

Home	Garage	Sean (friend)	Questions for Geary
Removed stereo and rewired antenna and accessory lead—it now works properly! Tested ECU and laptop hookup.

June 16th, 2002

Home	Garage	Sean (friend)	Questions for Geary
			Went to Emerald and found out Geary had stuck me with a crappy old ECU. Got the updates and software and now it works ok.

April 27th, 2002

Home	Garage	Sean (friend)	Questions for Geary
Created very trick-looking bonnet stay	Adjust shifter for better gear engagement	Bleed brakes (again!)	Missing gaiter on right rear wheel tie-rod
Velcroed floor mats	Place for glasses/storage		Missing nut on left rear wheel caliper assembly
Replace undertray screw	Brake light sensitivity		Broken mounting tab on fuel tank
Tighten alternator bolt	Emergency brake light—low on brake fluid...		Right rear wheel camber
Raise front ride height Stiffen front shocks	Rear brake pad-inspected…ok
	Steering adjustment—non-adjustable

Start	9am.
Gathered tools, set up area, ran around trying to find planks. This was not fun! First I had to get the pieces of wood and position them between the lift so the car would sit on them and be high enough to get the lift arms under the car. Then I had to jack it up with a floor jack to remove the undertrays so the car could be raised up from the correct jacking-up points. Then I had to undo the clevis pin for the handbrake cable, detach the shifter cables, and the throttle cable. I also had to reach above the fuel tank and undo the hose clamps for the filler and breather tubes, and then wrestle with the very stiff tubes. Then I could unscrew the three bolts holding the fuel tank and drop it down onto another hoist. It was now	11 am.
Before trying to lower the fuel tank, I had to also disconnect the fuel pump electrical connection, as well as the fuel and return lines. This was very difficult because there wasn’t too much clearance to reach and do this, either from the access panel at the top or by reaching up from the bottom. It was now	12.30 pm.
Having dropped it down, I unscrewed the fuel pump, to find no gasket whatsoever. No wonder the bloody thing leaked. It was two metal plates screwed together. And even the screws weren’t tight!	1.30 pm.
I put in a rubber ring, tightened the screws, then poured sealant all around. When I tested by tilting the tank, it still leaked, but a little less. I put on more sealant and tested again. It still leaked! I finally found out that the pump’s fuel line plastic coupling had a hole in it and was leaking. I had to drain the tank, fill it with water, and then use a soldering iron tip to melt the plastic together. Then I drilled out the pipe so it was the same diameter as before. End of leak.	3.45 pm.
Now it was time to get rid of as much water as possible. I borrowed a car and a jerry can, and went to buy some petrol. Then I flushed the water out of the tank by emptying, filling with some fuel, sloshing it around, emptying, and repeating! It was now	4.45 pm
Reassemble fuel tank. Reattach the stiff filler neck and brether lines (very difficult) and tighten hose clamps, while the alternator heat shield’s sharp edges were slicing the back of my hands to bits.	6.15 pm.
Reconnect lines.	6.30 pm.
Test fuel tank by starting fuel pump. It wouldn’t work because the float was too low. So I had to lower the car, put fuel in, raise it again, then turn on the ignition. When I did so, fuel started spraying all over on top of the tank! Luckily, it was a loose fuel line (the clip was bent). I disconnected the line, mopped up the mess, and took out and fixed the plastic clip with the soldering iron. Then I reconnected it all	7.30 pm.
Finally, testing showed there were no more leaks!!!!!!
Reattached the access panel.	7.45 pm.
Lowered the car. Then jacked it up with the floor jack. And reattached the undertray panels. I hate doing this. The middle panel was bent because I not placed the jack properly earlier on, so I had to bang that straight with a mallet	8.30 pm.
Lower car, reattach roof clamshell, test everything and back out and remove and dispose of wood	8.45 pm.
Pack up my stuff.	9 pm.
Clean up area (fuel, glue, packaging, rubbish, etc. was everywhere!!!	9.15 pm.
Put things away!	9.30 pm
Search web for 1978 Porsche Turbo motor for Mike	9.40pm.
Drive off	10 pm.

Eternal thanks Mike Malenko who allowed me to use his garage from 9am to 10pm. What a guy! And to Rob for all his help with the melted plastic business. And to Peter for allowing me to use his amazing tool chest. I could never have done it without you!

April 22^nd, 2002

Home	Garage	Sean (friend)	Questions for Geary
Replaced alternator bolt Adjusted idle Adjusted front clamshell latch Cleaned front storage area Tightened brake master cylinder connecting lines Added brake fluid Cleaned footwells Used industrial Velcro to make floor mats stay put Thoroughly cleaned and washed car Secured rear undertray with proper bolts Thoroughly cleaned engine Put cap on washer bottle Added windshield washer fluid Put on correct nuts and bolts on body panels Secured license plate Made mini tool kit with flashlight, wrenches (spanners), allen keys, jumper cables, tow rope Made stay for front clamshell Adjusted front and rear shocks Adjusted rear spoiler	Put on rubber lining on undertray Adjusted and rerouted cables under car

April 4, 2002

Home	Garage	Sean (friend)	Questions for Geary
Replaced battery Download and study manual Put in sill protectors Attach fire extinguisher Fix peeling window trim Fix peeling door trim Put padding around items in engine bay Put padding under clamshell Put padding and tape around front storage compartment cover Adjust fasteners for rear clamshell Space for documents Attach license plate securely Wind and noise proofing Fix windows Fix driver’s door Remove clips, etc from inside both doors Remove loose parts Secure various items in front compartment Secure battery properly Adjust length of air-filter hose	Tighten loose cables Tighten hoses in engine bay Adjust handbrake Rubberize undertray	Charge battery Cover up alarm light Cover up license plate lights from inside Secure loose side marker lamp Tighten battery terminals

Loose bits

-Front compartment

Battery not fastened down properly. Removed, cleaned area, secured properly now. Found loose washer and a 10mm spanner—removed.

Adjusted latch.

Cover rubbed on edge of front clamshell—covered it with clear 3M film.

Found flat-blade screwdriver in chassis member-removed!

-Doors

Interior door handle adjusted and window mechanism fixed.

Loose clips removed.

Clips cemented in place.

-Engine compartment

Used neoprene bits with epoxy in strategic locations to cushion cover.

Rerouted hoses and cable tied to clean up and decrease vibration

Alternator bolt replaced and tightened.

Secured ECU and wiring.

Covered up back of license plate lights so they don’t shine into engine bay (very distracting at night—it’s now much improved).

-Cockpit

Loose passenger footrest vibrating against protruding bolt head – used grinder to make notch for bolt head and stuck footrest down with industrial Velcro. Fixed nicely.

Used industrial Velcro to attach fire extinguisher against rear bulkhead.

-Exterior

Used industrial Velcro and double-sided tape to secure license plate after the first one fell off.

Used expoxy to secure loose side marker lamp