Wednesday, 30 November 2016

Porsche 944 Sill Rust Replacement

The sills on my Porsche 944 are in severe need of replacement as seen in previous photos. I've been struggling to find a suitable welder to work on them. Today I found a 944 specialist who appears to have done many 944 sill replacements where the level of rust damage is very similar to my car. After a short conversation I was very impressed and am hoping to pop in next week to have a chat.

I'll update the blog with more details but Retro restorer looks very promising as an option for repairing my 944.

http://retrorestorer.co.uk/rusty-and-crusty

The title of the blog sums it up perfectly!

Porsche 944 Sill Rust Replacement
Porsche 944 Sill Rust Replacement

Porsche 944 Sill Rust Replacement

Sunday, 27 November 2016

Removing Fuel Line Clips Porsche 944

The fuel lines on my 944 are rusted to pieces so need replacing. Once all the rear drivetrain and suspension is removed the next step is removing the fuel line clips. On the Porsche 944 the fuel lines and brake lines are held in by rubber and metal clips retained with a plastic screw. I found a Torx T25 fitted inside the plastic screw clip to undo them.

 

Rusted fuel lines porsche 944


Rusted fuel lines porsche 944
Rusted fuel lines porsche 944

Tuesday, 22 November 2016

Porsche 944 Replacement Sills Panels

I posted photos of the rotten sills on my 944 but have now managed to obtain a pair of brand new genuine replacement sill panels to use on the car. These are available directly from Porsche for around £600 but I found a seller on Porsche Club GB who no longer owned a 944 that was disposing of spare parts.

Porsche 944 Replacement Sills Panels
Porsche 944 Replacement Sills Panels

Porsche 944 Replacement Sills Panels


Next stage is to arrange for the rusted areas to be cut out and the welding to be done

Sunday, 20 November 2016

Porsche 944 2.5 Exhaust Parts Layout

The Porsche 944 complete exhaust layout. This shows 2 sections, rear with back box and front with 2 pipe connection to manifold.

So far I'm struggling to find the front section, rear seems to be easily available but the manifold 2 branch part doesnt.

Porsche 944 2.5 Exhaust Parts Layout
Porsche 944 2.5 Exhaust Parts Layout


Wednesday, 16 November 2016

Porsche 944 Rusting Sills

What can appear to be a solid piece of bodywork can be hiding some scary rust underneath! These are some photos of the sills of my Porsche 944 front on and looking inside from the side. The sill is full of broken pieces of rust and the outer side is basically paint holding pieces of rust together. 

Next stage is to start digging and find out how the inner sills are looking!
Porsche 944 Rusting Sills
Porsche 944 Rusting Sills

Porsche 944 Rusting Suspension mount point
Porsche 944 Rusting Suspension mount point



New 944 Gearbox Mount

One of the items I knew I wanted to replace while the rear of the car was in pieces was the gearbox mount. I try to get parts from my local Porsche dealer, OPC Tonbridge but unfortunately the part was on back order and would not arrive for a couple of months. Having looked around several suppliers and drawn a blank I found that Eurocarparts had a Porsche 944 gearbox mount available shown as "VM" brand and with their 30% discount code it was a decent saving compared to the Porsche centre.


Despite the website saying the part would be in stock within 7 days I soon received an email that the mount had been delayed and would now be a couple of weeks. Fortunately the car is still being taken apart so there was no rush for the part to be available.


Roll on a couple of weeks and the parcel arrived with the gearbox mount in. Imagine my surprise to open the box and find that the part is a genuine Porsche mount exactly as I would have got from the Porsche dealer! Something else to tick off the list for jobs!

Thursday, 10 November 2016

Porsche 944 Rear Fuel Lines Replacement

After seeing my Porsche 944 on the ramp it was clear that the rear Fuel Lines needed replacement. Unfortunately it isn't an easy job without removing most of the rear of the underneath of the car but that also gave an opportunity to refresh lots of tired components at the same time as well as examine common rust spots in detail.


So having prepared the garage for the car to sit in for a few weeks (now turning into months!) the first job was to jack the car and support on stands. There is a point just in front of the rear arches that will support an axle stand so we raised the car as high as we could to give the best access.

First job was to remove the wheels, then brakes, calipers followed by discs. Once discs are off you can remove the drive shafts. I've been bagging up all the bolts in separate bags labelled to keep a track of where they need to go back afterwards but quite a few are likely to be replaced with new parts.