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1987 Testarossa suspension and brake refresh. TR #71387

Discussion in 'Boxers/TR/M' started by kartboy1234, Mar 24, 2017.

  1. kartboy1234

    kartboy1234 Formula Junior

    Nov 10, 2014
    533
    Palos Verdes, CA
    Full Name:
    Michael L
    Hey everyone, I am working in refreshing my suspension. I have the brake calipers out for a rebuild, I have new pads and have rear rotors, fronts need to be ordered.

    I will be painting or powder coating the A arms and sway bars, cleaning up the uprights, derusting and painting/undercoating any rusty areas. I have new factory bushings on order and they should be here soon. If I find anything else that needs work I will address it.

    I will be using this thread to document my progress and maybe asking a question or two. Have any advise?
    Thanks
    Michael
     
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  3. kartboy1234

    kartboy1234 Formula Junior

    Nov 10, 2014
    533
    Palos Verdes, CA
    Full Name:
    Michael L
    #2 kartboy1234, Mar 24, 2017
    Last edited by a moderator: Sep 7, 2017
  4. kartboy1234

    kartboy1234 Formula Junior

    Nov 10, 2014
    533
    Palos Verdes, CA
    Full Name:
    Michael L
    By the way, the rust is just surface. The flakey stuff is rubber undercoat. No need to be alarmed. All of these issues will be dealt with.
     
  5. kartboy1234

    kartboy1234 Formula Junior

    Nov 10, 2014
    533
    Palos Verdes, CA
    Full Name:
    Michael L
    #4 kartboy1234, Mar 24, 2017
    Last edited by a moderator: Sep 7, 2017
  6. 302Tim

    302Tim Formula 3
    Silver Subscribed

    Jul 2, 2011
    1,182
    Northern California
    Full Name:
    Tim
    On my list to do but haven't tackled yet so I can't really help but there has to be a way to get to the fork nuts to pull that A-arm--Brian Crall once said that's how they were originally installed: A-arms already bolted to forks, then forks installed/shimmed as needed. Is it the front fork or rear fork nut you can't reach (or both)? The front maybe if you moved the A/C hoses going down into the pocket behind the fork?
     
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  8. kartboy1234

    kartboy1234 Formula Junior

    Nov 10, 2014
    533
    Palos Verdes, CA
    Full Name:
    Michael L
    #6 kartboy1234, Mar 25, 2017
    Last edited: Mar 25, 2017
    I was able to get the front fork nuts off. I used a big crescent wrench and wd40. I had to clean off some undercoating but was able to get it off. I have everything out of all corners. I couldn't get the axles out of the hubs, so I will clean it up and paint them in the car. I don't believe that the suspension has ever been off the car. An impact air ratchet is a great thing to have.

    I have the whole car on a portable car lift, so that makes getting under it safe and easy. I'll post some more pictures later.
     
  9. kartboy1234

    kartboy1234 Formula Junior

    Nov 10, 2014
    533
    Palos Verdes, CA
    Full Name:
    Michael L
    #7 kartboy1234, Mar 25, 2017
    Last edited by a moderator: Sep 7, 2017
  10. kartboy1234

    kartboy1234 Formula Junior

    Nov 10, 2014
    533
    Palos Verdes, CA
    Full Name:
    Michael L
    #8 kartboy1234, Mar 28, 2017
    Last edited by a moderator: Sep 7, 2017
    Well parts are coming in. This is what about $700 in bushings and parts look like. I am waiting on tie rod ends and shock bushings. All in this project will probably be $3000 total.

    As an aside, are people enjoying seeing the progress? I haven't received too many responses on the thread. I can keep posting if people like it.
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  11. lear60man

    lear60man Formula 3

    May 29, 2004
    1,801
    Los Angeles
    Full Name:
    Christian
    Yes please continue to post progress pics. I love this stuff.
     
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  13. kartboy1234

    kartboy1234 Formula Junior

    Nov 10, 2014
    533
    Palos Verdes, CA
    Full Name:
    Michael L
    Perfect, I have one fan. I will keep adding updates.

    I have a spring compressor arriving tomorrow. I will be disassembling the shocks and figure out if I want to paint or powder coat the springs. I also found a set of Koni stickers that match the shocks for sale for $5 for 4 stickers. So I will get two sets and have two stickers for my tool box.

    I have a request for a quote to rebuild my master cylinder. It wasn't too bad inside once I took it apart, but the seals are old and should be replaced. We will see what that quote looks like.

    My next big hurdle is to remove the bushings from the shocks and the suspension. I really don't want to mess this part up. I have been getting confused by reading how to replace the bushings on a 308, only to fond out that they aren't similar. The 308's bushings are welded in.

    Here's my question, are the bushing just a press fit?
     
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  14. kartboy1234

    kartboy1234 Formula Junior

    Nov 10, 2014
    533
    Palos Verdes, CA
    Full Name:
    Michael L
    #11 kartboy1234, Mar 28, 2017
    Last edited by a moderator: Sep 7, 2017
    I was able to use a scuff pad on an air die grinder this weekend to clean some of the rust off of the master cylinder. It turned out decently well. I may use a rust converter and paint it. But that's after I see if it can be rebuilt.

    I measured my mini stickers with calipers, turns out my power wash of the shocks this weekend removed some of the stickers. But from what I could measure it seems to be around 1.4"x1.4". Koni sells new stickers on their site, so maybe those will be a better match than the ones I found on eBay. I'll send them an email.
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  15. 1TRICK6

    1TRICK6 Karting

    Aug 28, 2014
    150
    So. Cal (L.A./O.C.)
    Full Name:
    Jim
    +1 more fan.
     
  16. kartboy1234

    kartboy1234 Formula Junior

    Nov 10, 2014
    533
    Palos Verdes, CA
    Full Name:
    Michael L
    #13 kartboy1234, Mar 29, 2017
    Last edited by a moderator: Sep 7, 2017
    I have been researching the stickers for the shocks. I received an email from Koni and the sticker they sell is 1.6"wide by 1.4" tall, this could be the original size, but the sticker is not identical. Compare the picture of the shock with the sticker on it, now compare it to the Koni sticker from their site. It's different at the top mount.

    The picture of 4 stickers is from eBay, they measure 1.2"x1". They look basically identical to the originals but they are slightly smaller. I will take a shock apart and measure a sticker more precisely. The eBay seller can scale it up I think.

    More to come.
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  17. raysur

    raysur Formula Junior

    May 3, 2008
    442
    So. Cal.
    Full Name:
    Jeff
    Fan #3 :D

    Keep it going!
     
  18. kartboy1234

    kartboy1234 Formula Junior

    Nov 10, 2014
    533
    Palos Verdes, CA
    Full Name:
    Michael L
    Thank you all. I have a request, does anyone have any pictures of the front brake air ducting? Mine was ziptied in place. I can't imagine that would be original. I found the ducting on amazon.
     
  19. PINNIN512

    PINNIN512 Formula 3

    Aug 30, 2002
    1,014
    California
    Full Name:
    David
    I can help you if you need these Koni decals. I am just down the hill in Torrance. I made some extra for my Boxer.

    Dave
     
  20. bpu699

    bpu699 F1 World Champ
    Silver Subscribed Owner

    Dec 9, 2003
    13,595
    wisconsin/chicago
    Full Name:
    bo
    When I was doing my major I thought about replating/powdercoating the suspension...

    I couldn't get up the courage to send irreplaceable bits out of state, to potentially get lost, to get them done...
     
  21. kartboy1234

    kartboy1234 Formula Junior

    Nov 10, 2014
    533
    Palos Verdes, CA
    Full Name:
    Michael L
    David, that would be fantastic. Thank you for the offer. Do you have 6 available for me to buy?

    Yea, I'm a little nervous about giving the suspension bits to someone to powder coat, have them over spray in bolt holes and bushing holes, so I will be painting them myself. The paint has lasted 30 years, so we will see how long my paint lasts.
     
  22. kartboy1234

    kartboy1234 Formula Junior

    Nov 10, 2014
    533
    Palos Verdes, CA
    Full Name:
    Michael L
    Question for people, what color is your master cylinder? Mine was black, but I have seen replacements be silver. I would like to have it done right.
    Thank you
     
  23. kartboy1234

    kartboy1234 Formula Junior

    Nov 10, 2014
    533
    Palos Verdes, CA
    Full Name:
    Michael L
    I am sending my master cylinder out for rebuilding. There is a company called Karps power brake service. They are somewhat local to me. For $175 they will rebuild the master cylinder with new seals, for $50 ish more they will powder coat it either silver or black. I figured I would spend a ton of time trying to find seals that fit the thing, so $175 isn't too bad to save me time. Plus I know that it's done right.
     
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  24. Chief20123

    Chief20123 Karting

    Dec 22, 2012
    169
    Melbourne,Australia
    Full Name:
    Fred
  25. kartboy1234

    kartboy1234 Formula Junior

    Nov 10, 2014
    533
    Palos Verdes, CA
    Full Name:
    Michael L
    Thank you so much for posting that. I had read through that post a few years ago but forgot about it. Now I know to cut the ends off of the bushings. That's what I had thought to do for them.
     
  26. tommydogs

    tommydogs Karting

    Nov 9, 2016
    135
    Los Angeles, CA
    Full Name:
    Tommy Robinson
  27. vincenzo

    vincenzo F1 Rookie

    Nov 2, 2003
    3,053
    #24 vincenzo, Mar 29, 2017
    Last edited by a moderator: Sep 7, 2017
  28. kartboy1234

    kartboy1234 Formula Junior

    Nov 10, 2014
    533
    Palos Verdes, CA
    Full Name:
    Michael L
    Thank you for posting that. Mine may come out glossy but that's ok. It's good to know that the floor under the master cylinder is semi gloss black. Mine is a nice shade of flakey rusty red.
     

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