Right off the bat I know this thing needs:
Valve adjustment
Valve cover seal kit (and potentially valve covers--as the original are magnesium and prone to warping). Just received these from Pelican...now I just need to finish studying-up on valve adjustment (and procure the tools)
Timing cover seal kit. Just got parts from Pelican--hope to start this weekend.
Oil return line (found a local hydraulic hose company that can repair--they're also doing lines for Napelton's race team). Hope to pull this weekend to take to them next week.
Oil return tubes. On hold pending valves, timing and tank--can't do everything at once.
Miscellaneous seals and tubes around the oil tank (still investigating the scope of this leak)
Things it doesn't necessary need but must be done:
Suspension...this thing is riding like a 4x4 and the front left strut is leaking (hey--it's 25 years old). I'm thinking H&R reds with Bilstein HD dampers.
Exhaust...antiquated cat into a primary muffler into a secondary muffler. Incredibly heavy, overly complex and reserved. I'm thinking cat and secondary bypass. I've pulled the cat section so I'm thinking I can take that up to one of my 'cash only' local establishments for a straight section. Also looking for a secondary bypass--which is essentially an elbow out the back of the car from the primary. From what I've heard, this should drop ~25 lbs from the rear of the car and deliver a proper flat 6 sound.
Wheels...the not-so-bright previous owner had 996 rep's installed. While the fronts were a passable 8" (albeit ill fitting) the rear's were a disastrous 10". I don't care what the ET or camber is--a 10" rear does not fit a NB 964. You're either too overflush to the fender or perilously close to your oil line. Watching the boards for a replacement set now--at which time these will go on the market. I should of known there was a reason he had 20mm spacers on the rear.
Maintenance...I've got some compatible trans fluid in the garage so I'll do that, had to drain the oil for the valve adjust so that and the filter will be fresh, fuel filter was cheap so I ordered that, might as well change the plugs while I'm in there (need 12--damn fancy dual spark).
Disassembly:
Slow. Think dissimilar materials, 25 year old heat cycled and corroded hardware. Lot's of Liquid Wrench and lot's of busted studs and screws. Almost there though--just need to pull the heat exchanger off the drivers side cylinders to disconnect an oil line. Also need to buy another case of brake clean.
