Up and down

I finally got the air suspension working. Well, at the front anyway as the rear struts are still on their way.

Also the engine is running like before and basically the car is now driveable. Still a lot to do but I'm happy how things are going now.

Engine in

I finally lifted the engine back into the car. I installed new intercooler, much bigger than the old one, and it fits just fine. I haven't tried the hood yet but hopefully it fits also. I also made some strut support bars as the body felt quite lively. Air springs are also a little stiffer at ride height so extra support really is needed.

This is the lowest it now goes. Front is sitting on bump stops and as I still don't have air struts at rear it will not go lower.

Looks just about right at rear for driving height, front needs to be a bit higher.

Finally some progress. I got the front struts installed and measured that I would still need 20mm more drop if I want to get the wheels to touch the arc. Well, this will do for now as getting lower means getting new inserts and strut sectioning. I just hope the bags are stiff enough at drive height.

I also got the solenoid valve and suspension management wired. Basically only things that are missing are the rear struts and compressor. I will have the compressor hopefully this week but the struts are on a ship in the middle of Atlantic so it will take almost a month until I get them.

I also glued the dash top on. It fits better than I had thought after some cutting ahd heating but it's still a plastic cover. 

I also got the wheels colored. I got tired of the polished lip and now, well, they're golden. It's a bit too bright and reddish but I can always redo them next winter. Now I will concentrate getting the car driveable.

Front struts

I had to make spacers for front bags as the thread on the strut body was bigger than bag's ID. Now I can adjust the height / stiffness at least a little.

Suspension work

I finally got the electrics done so I can now work on the suspension. I installed the front height sensors and routed the air line for front bags. Great thing with the sensors are that they are mirrored and can be mounted at the same spot both sides. 

I didn't shorten the pushrod yet as I need to get the suspension range fighred out first. Probably will do that when I get the car on lift.

Looks like I can fit all but the tank to the spare wheel well. I haven't got the compressor yet but it will fit.

I drilled the holes too high as the moustache bar is right behind the well and there's really no room for stiff line.

And the electrics are done, only few connectors for dash harness are missing. All is hidden behind the dash and dash can be removed without disconnecting all wires.

After few boiled top coats I finally managed to paint the engine bay. Now I only need to finish the wiring for the lights, wipers and such and engine can be lifted back.

This is quite a mess. I decided to remove the wiring harness from the dash and mount it to the chassis. At the same time I will strip all unnecessary wires that are no longer needed.

Some bodywork

Now as the engine is out it was good time to fix all the little issues there was in the engine bay. I welded a few holes shut and removed all the rust and loose paint there was. Strange thing as the car was painted no more than two years ago. I'm sure this time it will last.

I also stripped all the electrics out and now I'm totally lost with them. But anyway they will be replaced and all the obsolete wires will be left out.

New intercooled did not fit without modifying the radiator support panel. So it's totally gone now.

I also made removable front apron. Makes engine removal much easier.

Engine bay in primer. I haven't got the paint yet but this should be done next week so I can install the engine and continue with suspension.

I like doing things twice so I also cut the rear wheel arch. I got 30mm more space and that's just about as much as there was. I will try to weld this with tig to avoid burning the paint. Let's see how that goes.

Time for good old out and in

I decided to change spark plugs and what's a better place to change them than garage floor? OK, at the same time I will also change the clutch and some other smaller things. This begins to remind me of how it was with my VW's, engine and gearbox out every winter and couple of times during the summer also.

I didn't even remember how heavy package this is. But there it is, ready for disassembly.

Now when the engine is out it would be easier to strip off all the electrics and replace them with universal harness. I'm also considering floor reinforcements of some kind. Let's see what I can do and afford as the air suspension is taking way more than I expected. I can't use Universal Air springs at the rear as there's not enough space. So I will have to come up with different, and more expensive, solution soon or I will run normal springs next summer.

OK, driving season has been over for a month now and the car is down at the garage. No big plans for the winter due to time and budget restraints but at least clutch and suspension need attention. I'm having hard time on deciding which clutch to install. I already have Nismo single coppermix waiting for installation but I'm not sure it will hold. I would not want to go for twin disc as this is a daily driver and having easy clutch is almost a must, but then again slipping clutch is even worse than harsh engagement.

Here's a sneak peek on suspension upgrade. I want to get the car lower and air seems to be the only way as I still need to get into the garage and that's not possible with low car.

I got universal air aero sport's at front and they seem to fit just fine. I haven't tried them at the rear, but looks like I have to come up with a different solution as the strut tower is smaller.
 

As there was nothing else to do with the car I installed the almost mandatory duck tail. It really needs emblem now as it looks quite plain without. And while the car was in the garage I installed a pair of Swedish Recaro replica seats as well. Although the original seats do look great they are horrible to sit at. I will get them reupholstered to match the rest of the interior as soon as driving season is over. But anyway hitting the limiter on 4th felt much safer with the new seat.