04-13-2024, 11:13 AM
Name is Kevin, I am with CVMA Combat Veterans Motorcycle Association and I usually go by my Road Name Calvin.
I am an aircraft mechanic by trade, specializing in helicopters, with over 40 years of experience. I used to have my own (out of the house) business when I lived in Portland, Oregon, specializing in VW air-cooled stuff.
Working on things is my hobby, and there is little I cannot do by myself. I stumbled on my 968 Cab via my mother-in-law. A friend of hers that she used to live next to passed away, and she was contacted and asked to help sell the house. Well, that is when she was told that there is a car in the garage that has been sitting for over 8 years. She contacted me, and I went and took a look at it. I was not looking for another project and I was just about ready to start building a new motorcycle (AKA a Bobber, from a 1976 Yamaha XS650) when this deal fell in my lap. I couldn't argue with the price, so I picked it up.
The car had hit something on the road and destroyed the lower front of the bumper. The hack mechanics that this guy paid to work on the car removed lower panels that they felt it did not need, and more damage was done with the inner fender wells rubbed through the tires. The interior was okay, the driver's seat back had a major rip in it. It had a new top, but it needed adjusting. The list goes on and on, and it has taken me over two years to fix one problem at a time to get where I am today.
Starting in the front of the car.
I repaired the front bumper, but I had to pull molds off one side and make scab parts fit on the other side. (That was a process)
Replaced all under panels and repaired the inner fender wells (Yes, you can, and no one can tell it was done; amazing what plastic-wielding products are out there)
Rack and Pinion blew out after I just got it drivable, so that was just replaced.
Currently in the process of finally fixing the oil seepage from the Oil Cooler housing that is mounted on the side of the engine. Decided to also do the cam checks and replace the water pump and front seals while I have the engine apart. (again, its on the list)
Rebuilt and pressure-cleaned the fuel injectors and, of course, cleaned out the full fuel system from rotten gas.
Drive Train
I got new pads all around, checked the brake calipers, and rebuilt them anyway with new seals and paint. (This was a good thing; again, the Hack mechanics who did work on it did not install the driver's side inner parking brake shoes and the spring correctly; if I had driven more, I am sure it would have caused some real damage.
The brake master cylinder was replaced.
Clutch Master cylinder was shot, it took two days to remove the old one, the clevis was so worn out and the pivot pin was cammed, thanks to my neighbor (female) with small hands was able to get in and remove it for me. Installation after that with new parts was a breeze.
Clutch Slave cylinder was rebuilt. Took forever to clean up the bore for the cylinder but its perfect now.
Interior
Instrument cluster speedo did not work, or amp or fuel. The car came with a replacement cluster that the speedo was fixed, but again, a bunch of the other items did not work. Took some time and electrical engineering but now all is fixed.
Was working on the cluster and that's when I saw how bad the back lighting was, found a LED kit on eBay for $85. Saw what the kit was and for a total of $27, I have a instrument cluster that will blind you if you turn it up all the way. (have photos on what to do and will instruct for those who are interested.
The car came with a Pioneer Super Tuner (from the 90s) and replaced it with the new Porsche retro radio (Highly suggest that to anyone)
The seats were shot with all the bushings destroyed over time. Shopped around on eBay and rebuilt the power seats for under $200.
Took the seat back in and had the one side that was ripped replaced. I know how to do leather work so I stripped down the leather, re-tanned it all and sealed it all. Looks like new
Door panels and dash had cracks from heat, after watching a few YouTube videos I repaired them all and no you can not tell.
Re-died the carpet and floor mats and sealed them, again looks new.
New shifter boot and cleaned up the shifter knob.
Replaced the glove box door with after market aluminum hinges. (again highly suggest them)
All interior lights now are LED
Air conditioner system fully rebuilt, recharged.
The center console. The car had a 944 tray in place of the 968 that should have been there. Bought the correct bottom and hinge and bought a top cover on eBay that was a new leather top for $50. That's when I discover it was just the leather and not the top. Ended up actually building a mold and making my own top fiberglass cover, it is covered with memory foam and after the new cover was installed you can not tell the difference. Ended up cutting the factor plastic one piece hinge and installing doll house hinges for the cover. (90s design will brake every time)
Body
Front bumper rebuilt
Side lower skirts repaired
Seals replaced
repainted bumper, front fenders and lower panels.
Rebuilt the headlight pop up motors (working perfect now)
All bulbs are now LED
So, still have MILES to go on the car. Need to rebuild the brake anti-lock module (Not looking forward on that)
And I need to reset the warning light because of the drivers airbag issue.
Thats my story.
What am I going to do with the car when I am done? Still not sure yet, but for now its keeping me out of the bars!
Kevin, AKA "Calvin"
I am an aircraft mechanic by trade, specializing in helicopters, with over 40 years of experience. I used to have my own (out of the house) business when I lived in Portland, Oregon, specializing in VW air-cooled stuff.
Working on things is my hobby, and there is little I cannot do by myself. I stumbled on my 968 Cab via my mother-in-law. A friend of hers that she used to live next to passed away, and she was contacted and asked to help sell the house. Well, that is when she was told that there is a car in the garage that has been sitting for over 8 years. She contacted me, and I went and took a look at it. I was not looking for another project and I was just about ready to start building a new motorcycle (AKA a Bobber, from a 1976 Yamaha XS650) when this deal fell in my lap. I couldn't argue with the price, so I picked it up.
The car had hit something on the road and destroyed the lower front of the bumper. The hack mechanics that this guy paid to work on the car removed lower panels that they felt it did not need, and more damage was done with the inner fender wells rubbed through the tires. The interior was okay, the driver's seat back had a major rip in it. It had a new top, but it needed adjusting. The list goes on and on, and it has taken me over two years to fix one problem at a time to get where I am today.
Starting in the front of the car.
I repaired the front bumper, but I had to pull molds off one side and make scab parts fit on the other side. (That was a process)
Replaced all under panels and repaired the inner fender wells (Yes, you can, and no one can tell it was done; amazing what plastic-wielding products are out there)
Rack and Pinion blew out after I just got it drivable, so that was just replaced.
Currently in the process of finally fixing the oil seepage from the Oil Cooler housing that is mounted on the side of the engine. Decided to also do the cam checks and replace the water pump and front seals while I have the engine apart. (again, its on the list)
Rebuilt and pressure-cleaned the fuel injectors and, of course, cleaned out the full fuel system from rotten gas.
Drive Train
I got new pads all around, checked the brake calipers, and rebuilt them anyway with new seals and paint. (This was a good thing; again, the Hack mechanics who did work on it did not install the driver's side inner parking brake shoes and the spring correctly; if I had driven more, I am sure it would have caused some real damage.
The brake master cylinder was replaced.
Clutch Master cylinder was shot, it took two days to remove the old one, the clevis was so worn out and the pivot pin was cammed, thanks to my neighbor (female) with small hands was able to get in and remove it for me. Installation after that with new parts was a breeze.
Clutch Slave cylinder was rebuilt. Took forever to clean up the bore for the cylinder but its perfect now.
Interior
Instrument cluster speedo did not work, or amp or fuel. The car came with a replacement cluster that the speedo was fixed, but again, a bunch of the other items did not work. Took some time and electrical engineering but now all is fixed.
Was working on the cluster and that's when I saw how bad the back lighting was, found a LED kit on eBay for $85. Saw what the kit was and for a total of $27, I have a instrument cluster that will blind you if you turn it up all the way. (have photos on what to do and will instruct for those who are interested.
The car came with a Pioneer Super Tuner (from the 90s) and replaced it with the new Porsche retro radio (Highly suggest that to anyone)
The seats were shot with all the bushings destroyed over time. Shopped around on eBay and rebuilt the power seats for under $200.
Took the seat back in and had the one side that was ripped replaced. I know how to do leather work so I stripped down the leather, re-tanned it all and sealed it all. Looks like new
Door panels and dash had cracks from heat, after watching a few YouTube videos I repaired them all and no you can not tell.
Re-died the carpet and floor mats and sealed them, again looks new.
New shifter boot and cleaned up the shifter knob.
Replaced the glove box door with after market aluminum hinges. (again highly suggest them)
All interior lights now are LED
Air conditioner system fully rebuilt, recharged.
The center console. The car had a 944 tray in place of the 968 that should have been there. Bought the correct bottom and hinge and bought a top cover on eBay that was a new leather top for $50. That's when I discover it was just the leather and not the top. Ended up actually building a mold and making my own top fiberglass cover, it is covered with memory foam and after the new cover was installed you can not tell the difference. Ended up cutting the factor plastic one piece hinge and installing doll house hinges for the cover. (90s design will brake every time)
Body
Front bumper rebuilt
Side lower skirts repaired
Seals replaced
repainted bumper, front fenders and lower panels.
Rebuilt the headlight pop up motors (working perfect now)
All bulbs are now LED
So, still have MILES to go on the car. Need to rebuild the brake anti-lock module (Not looking forward on that)
And I need to reset the warning light because of the drivers airbag issue.
Thats my story.
What am I going to do with the car when I am done? Still not sure yet, but for now its keeping me out of the bars!
Kevin, AKA "Calvin"
