Das Smaragd RS2+ Coupe

[John B]

February 2010 - 996 Rears 2

Ok let's build it up and see where we get to

Take a rear strut

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Add the hub assembly and a RS2 front caliper carrier

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Add a vented rear disc from the 1st generation S8 @ 280mm x 22mm

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Place the hand brake caliper in a strategic location

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Have a peek

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[John B]

February 2010 - 996 Rears 3

Right then.....time for 996 rear caliper

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Stand back and admire handiwork.....

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Yup, disc hat height looks about right.....will have to watch that ABS sensor though.....

Now all I need to do is design the main caliper adaptor and the hand brake caliper adaptor then figure out how to make the handbrake work

Fortunately, there were other dark forces at work that made this task a whole lot easier : you can fast forward and read about the end results here http://www.s2forum.com/forum/showthread.php?t=62766 or you can continue to follow this voyage of discovery and see what plagued the small mind of a fella in Cumbria for several months! (Think I need to upgrade my processor!)

[John B]

February 2010 - Front CV Joints & suspension

Busy month this....

Bit out of sequence but did the front outer CV joints - they take the hammer of steering plus suspension and turned these into those - read about it on http://www.s2forum.com/forum/showthread.php?t=51266 - my first Sticky

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Also, made some of these: -

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The Boddies ain't bad either

I used the excellent thread by k.alle http://www.s2forum.com/forum/showthread.php?t=34701 to set up the Koni shocks and H&Rs.

[geryS2]

nice thread, great story of restoring your car, i m surprised by the amount of rust your cars do get in northern england & scotland,

just went to see an RS2 LHD with 8 year history in england and the body was rusted all over the place, wings, boot, ...not even talking of the underneath and drivetrain.... did not buy it....

cheers

[John B]

Rust

Yeah, the rust monster is bad over here. Must be a result of Winter salt and living where it has, near the sea

[John B]

Feb 2010 - Rear ABS cables

Anyone who has removed the rear struts on the coupe will know that the ABS cables run through the chassis from the strut to under the rear seat. Here's a cunning method to make sure everything goes back easily

Take the bench seat out the back and here's the ABS cable

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Disconnect the cable and tie your best knot with a piece of string

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Now go to the underside of the car and gently prise off the grommet through which the cable goes....

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....and pull gently until you see the cable

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Untie and make sure that you re-tie the string so that you don't accidentally pull it through

Re-fitting as they say is the reverse.....

[John B]

Feb 2010 - Rear Struts

First we need to get to the top of the strut by removing the parcel shelf support and then loosening the nuts: -

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[John B]

Feb 2010 - Rear Struts 2

Then we need to detach the rear brake caliper, support it (I used wire) and take out the ABS cables as per earlier pictures: -

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You can see also that I have detached the anti-roll bar links

[John B]

Feb 2010 - Rear Struts 3

Wow that (Whiteline) anti-roll bar is mucky and the rear sub-frame rusty

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[John B]

Feb 2010 - Rear Struts 4

.....and the link joint was a PITA to remove. It barely turned then the ball joint spun happily until some pressure was applied : -

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[John B]

Feb 2010 - Rear Struts 5

The drive shaft bolts were amazingly tight as they are torqued quite highly and didn't seem to have been loosened at all in the life of the car. IIRC I had to stand on the socket bar (when the car wheel was on the ground before I started) and even tapped them with a mallet: -

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[John B]

Feb 2010 - Rear Struts 6

Support the strut from below, undo the top nuts and hey presto there's a pair of struts : -

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Now comes the hard work of dismantling the struts and re-building the whole lot

[John B]

Feb 2010 - Rear Struts 7

Here's an OEM ARB drop link from Lemforder ready to go on.

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I scraped and painted the sub-frame in situ. In hindsight taking it off and blasting it would have been much easier but i had read scare stories of people trying to take sub-frames off and captive nuts shearing off so i opted for leaving it where it was

Here is a scraped and painted wishbone of the pressed variety fitted with Superflex bushes: -

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Now the tricky bit of putting them back. I use the jack to push them home whilst i tapped the bolts in.

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Here's a close-up of the bolt showing the 15mm and 17mm sizes.

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Now for the ball joint - out with the old and in with the new, tapping it into place: -

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[Rusty]

Lots of work there, it's worth it in the end BTDT.

[bilko0795]

Lots of hard work there just done my coupe complete rear overhaul and every thing on the rear now is brand new. It took two w/ends to fit all the stuff but well worth it. Nice looking jack by the way what brand is it ? and what was the cost I could do with one of those.