924Board.org

Smoothie · Posted: Tue Oct 11, 2005 4:44 am Post subject:

Messing with an old solenoid here the other day, I tested it and found it still works, so cleaned it up, sealed its' seams and cracks with epoxy and lubed it. The main thing I want to mention concerns the inaccessible innerds of the solenoid that can/will get corroded over time as can be seen in this pic -
<click>

That solenoid went from new to what you see there in remarkably short time - like 1.5 years. -But having it to dissect, showed what's inside and what can be done to rejuvenate an old corroded one, or apply some preventative maint to a new one. The "T" shaped part with spring you see at the bottom-center of the pic is the movable switch part that when pushed in by the piston, moves against and closes the contacts (that appear as rusted round metal pieces in the plastic part to the left) to power the motor. When assembled, all you can see of that "T" piece is its' copper end in the center of the cylinder as shown here -
<click>

The maint, (in addition to de-gunking and oiling the piston) would be to simply dribble some Liquid Wrench or whatever on and around the copper button, press it in to let the fluid flow into the sealed switch area, shake it around, then in the case of an old corroded solenoid - pound the button in repeatedly with the handle end of a small-enough screwdriver (or whatever you can comfortably fit in your hand and fit into the cylinder to do the job). -This will smack the "T" piece against the round contacts to dislodge any rust that's on them. Then dribble a liberal amount of Liquid Wrench in there again and shake to rinse. For a new solenoid, just dribble in something like silicone elect contact cleaner/lube and shake it around.
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"..it's made in Germany. You know the Germans always make good stuff."

'82 924T, US version, dark green metallic, 5 speed Audi 016G gearbox

augidog · Joined: 03 Mar 2003 Posts: 1360 Location: New Jersey

Smoothie, what is with the brown jumper wire on the solenoid? Is it for easier access when mounted?
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1978 924 95 mile daily driver.
Audi TB/POR174M/High Flow Cat/2.25" exhaust
I knew that positive thinking thing wouldn't work.

D Hook · Joined: 02 Nov 2002 Posts: 3156 Location: Omaha, NE

Tom: We should try this with your old one and see if we can get it to come back to life.

Good pics, good info. Thanks!
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'80 924 n/a SOLD

Smoothie · Posted: Tue Oct 11, 2005 9:44 am Post subject:

Tigger937 · Joined: 11 Apr 2004 Posts: 915

Anybody know of a good way to re-plate the contacts in the solenoid after cleaning in order to extend the life? Without plating, won't the contacts just wear out again in a short time?
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1981 931 (Concours)
1982 931 (Daily Driver)

"Think outside the box"

Tigger937 · Joined: 11 Apr 2004 Posts: 915

Or maybe there's a way to replace the contacts with something that's already plated?
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1981 931 (Concours)
1982 931 (Daily Driver)

"Think outside the box"

Smoothie · Posted: Tue Oct 11, 2005 4:02 pm Post subject:

The problem would be getting at the contacts, or getting the assembly back together again afterward because it has to be cut open. The thickness of the metal outer casing and the way it's roll crimped around the plastic end makes it impossible, as far as I can tell, to reassemble it securely. That's why I suggest to dribble some cleaner in around the copper button. That seems to be about all you can do to have any effect on the internals without rendering it useless.
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"..it's made in Germany. You know the Germans always make good stuff."

'82 924T, US version, dark green metallic, 5 speed Audi 016G gearbox

Mike924 · Joined: 12 Aug 2004 Posts: 2601 Location: IoW UK

Smoothie, I've thought of a new project for you.

You need to re-write the Haynes manual!

With the material and experience you have at your disposal, it's bound to be heaps bettter than the original!

Seriously, nice work, dude!
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1985 Porsche 924 'Lux', Kalahari Beige (my ex)
1993 Porsche 968 Coupe, Midnight Blue, 6 spd

'There is no substitute for a little grease under your fingernails.' - Chrenan, 924board.org

Tigger937 · Joined: 11 Apr 2004 Posts: 915

Yeah, I'll second that. ATTA BOY!!!

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1981 931 (Concours)
1982 931 (Daily Driver)

"Think outside the box"

Smoothie · Posted: Wed Oct 12, 2005 8:24 am Post subject:

Well thanks for the kind words, but no-thanks on the Haynes rewrite.

I did start a thread on Haynes misprints awhile back though, so some of those can be corrected at least.

-For anyone that might be concerned about turning their solenoid into a little combustion chamber by introducing a flammable de-ruster/lubricant into the switch area.. (Makes sense since you'd have air, fuel and spark in there.) I played with mine some more today

- dribbled in another 50 or so drops of Marvel Mystery Oil this time to give it a nice wintergreen scent, hooked it up and applied the 12V juice to exercise it... Got no signs of it wanting to blow up. -Obviously for the same reasons a flooded engine cylinder and wet plugs don't combust very well.
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"..it's made in Germany. You know the Germans always make good stuff."

'82 924T, US version, dark green metallic, 5 speed Audi 016G gearbox

Tigger937 · Joined: 11 Apr 2004 Posts: 915

Joes924Racer · Posted: Mon Oct 17, 2005 4:50 pm Post subject:

starters go in at least 2 ways ...

1. broken lug ( from overtightening).
2. heat they will finally cut out and not
get the torque to start the motor when warm.

Im on my second starter.

I had both happen. #2 happend and I went back to #1
and drilled off the regular screwdriver headed bolts then did
the same to #2.

Using #1 motor I put #2 solinoid switch onto it.
usen metric bolts I picked up from Nappa everthings
Turns over real easy now.
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1979 porsche 924 Na
1980 porsche Turbo 931GT Replica
Have u ever driven a turbo.