Assembling and final tests

Assembling started with wire harness insertion.

Prepared in advance front axle components were installed into dedicated place. Missing specific front shock absorber bolt locking plates were self fabricated to complete installation of the front suspension.

 Door striker latch iron adjustment and threaded attachment plates were completely destroyed by corrosion so we made adequate copies needed for door installation.

Prepared in advance pedal assembly unit was installed into place. New footboards were fabricated from laminated water resistant plywood.

Insulation layer was formed over the floor pan in the passenger compartment.

Before closing of any hidden cavities protective coating was applied, like here on main lamp housing internal surfaces. Tail lamps were installed and connected to the wiring harness. In this case European orange lenses were supplied, but wiring harness was from American version – there were needed some additional wiring adaptations.

All control cables, wires and pipes were led through tunnel to the rear of the car preparing it for engine installation.

Supplied luggage compartment insulation mats were glued into dedicated position. Fuel tank insulation material was formed over the top surface of the tank.

Fuel cock was overhauled. Picture shows that comparing to received repair kit most of fuel cock parts were damaged or missing. Missing tank attachment bracket was self fabricated. Fuel tank was installed into place and connected to the fuel pipe and wire harness. Unfortunately filling pipe of the new tank was of smaller diameter comparing to original one and it did not fit to other filler neck components. We had to produce additional intermediate spacers to match all new parts together.

Front and rear wiring harnesses were connected to the relays and fuse holder plate. Restored passenger compartment ventilation valves were fixed into place.

Unfortunately it was not possible to use received parts of rear reflectors as long as all parts except red glasses were damaged. Missing fuel tank cap seal was self fabricated from appropriate material.

At this stage body was separated from the special rig used during body repair and painting procedures thus giving a way for rear axle and engine installation.

Continuing assembling we threaded through the tunnel new main plus cable. New sealing rubber was glued around the luggage compartment opening.

  Rear torsion bars and suspension arms were installed. Preassembled power unit was immersed into the body. New engine and transmission supports were used during installation.

Restored wheels were fitted onto front and rear axles.

Rear wiring harness was connected to the electrical components located in the engine compartment.

New antenna was fixed into dedicated place.

Front wiring harness outlets were guided through channels to front lamp housings.

Received new distributor cap unfortunately was useless, since it had wrong design and did not fit onto our distributor. We were forced to buy appropriate distributor cap ourselves. All wires and pipes were connected to the engine.

One of delivered for installation front lamps was defective – attachment stud was not fixed into the lamp body. Lamp was repaired before installation. Front indicator lamps and all decoration grills were installed.

Preassembling of rear bumpers included installation of horns with exhaust funnels, attachment brackets and number plate illumination lamps.

Using new rubber and decoration mouldings rear view window was installed. Engine compartment lid was hinged into the place.

Windshield and preassembled front bumper were installed onto the body.

Braking system was filled with braking fluid and beaded.

Side doorstep decorations were tried on and attached by means of supplied bolts and using new plastic underlay and inserts. Completely new sets of doorstep top surface decorations were installed onto the doorsills.

Cavities in front of the doors behind front wheel arches were covered with protective coating prior to door installation. Sound insulation was attached to the inner door surfaces and door mechanisms were preassembled before door installation.

Engine hatch was installed to the restored hinges and adjusted for correct fit. Rear grills were cleaned and polished before installation into dedicated places.

Luggage compartment lid was preassembled installing front grip with Porsche crest and then fitted into the place.

Bumpers were furnished by restored attachment brackets and all bolted joints got protective treatment against corrosion.

New window washer pump was installed onto new floor panel and connected to the other system components by new hoses.

New interior light switches were adopted and installed into dedicated positions.

Using new rubber pads door handles were installed. New golden embellishers of the rear end were attached to the body.

New rear taillights and reflector pedestals were installed at the rear end of the body. New headlamps were installed and accordingly adjusted.

As chromed parts were received from re-plating side windows were assembled and installed into dedicated places.

Door windows were assembled and installed using re-plated frames and new door sealing elements.

As engine was tested all received decals were applied on dedicated locations.

Preassembled rear bumper was fitted into the place.

Restored gauges were installed on the dashboard and connected to reconstructed electrical system of the car.

All restored electrical appliances were installed onto the dashboard.

Metallic parts of the original seatbelts were restored and original belts were washed before installation.

Engine was tested and adjusted in various running modes.

Carburettors were paired and adjusted.

Steering system and braking system adjustments were made to start run-in tests. Unfortunately weather was not facilitating on-road tests of classic cars so we had to wait for the spring to hit the road.

Car was delivered Germany for the hand over procedure to the owner. Many Porsche restoration experts used this opportunity to express their opinion about the restoration quality to the owner.

Car was placed on the Riga Master Workshop stand at the 25th Technoclassica Essen exhibition proudly showing craftsmanship of our masters. 

It gained unabated interest of the visitors, enthusiasts and specialists attending annual Technoclassica event.