A bit of winter renovation

[Steve Brookes]

I decided the winter is the ideal time to get some bodywork issues on the 964 sorted out. First job was simply to replace the chipped and badly pitted windscreen. This should have been a straight forward job. However, despite there being no outward signs, the famous 964/993 rust under the screen was found:

Most of it was superficial rust but the right bottom corner was so bad that the lip had disintegrated:

So that had to be all cut and cleaned out and metal welded in to make the aperture good again:

After a bit more work to clean it up, it'll be ready for the new screen to go in:

The windscreen was not the main reason for the car going in for bodywork. There has always been a rot problem on the left rear quarter, around the light unit. This likely stems from a ding and subsequent poor repair, many years ago before I bought the car. Here's what the rot looked like with the light unit removed:

And here is what it looked like from inside the wheel arch:

So it was time to get a proper job done to sort the problem out. Bumper removed so that they can get to it:

We were hoping that it would be possible to weld in a new light box but the rot has gone too far:

So a good second hand rear quarter has been sourced and the boys are now at work removing what they need to of the old quarter so that it can be replaced and so that the rear cross member can be repaired.

More pics later as the work progresses.

 

[ray stobbs]

you will be happy when done steve but we know weve got to stay on top of rust probs they dont go away just get worse

 

[mcgc0]

Interesting Steve. Mine is at Daytona's at the moment (or has been since start Nov) so interested, nay nervous, of what they find. It's a screens out soda blasted job is what I've asked for. Certainly l/h screen bottom bubble rust and rear screen bottom too.

Annoyingly, under the rear quarters, especially anywhere right at the back with the lights, are perfect traps for any/all water and grime the rear wheels throw up. Unless it's an area that gets pressure cleaned often enough all sorts will hang in there promoting rust.

Insurance cough up for the new screen?

 

[Steve Brookes]

ORIGINAL: ray stobbs

you will be happy when done steve but we know weve got to stay on top of rust probs they dont go away just get worse

Totally agree Ray. I think we just have to accept that these cars need stuff doing from time to time. The alternative is to lock them in a garage and not use them...not really what I bought it for! []

 

[Steve Brookes]

ORIGINAL: mcgc0

Interesting Steve. Mine is at Daytona's at the moment (or has been since start Nov) so interested, nay nervous, of what they find. It's a screens out soda blasted job is what I've asked for. Certainly l/h screen bottom bubble rust and rear screen bottom too.

Annoyingly, under the rear quarters, especially anywhere right at the back with the lights, are perfect traps for any/all water and grime the rear wheels throw up. Unless it's an area that gets pressure cleaned often enough all sorts will hang in there promoting rust.

Insurance cough up for the new screen?

I think it's a case of just accepting that as they take things off there are likely to be things underneath that will need sorting out. I think you're doing the right thing to have the glass out as you know the job will be done properly.

Yes, you're right about the arches being exposed, so corrosion is really only a matter of time.

The screen is being done by a friend with a 964 who works for windscreen fitter. The screen is made by Sigla (sp?) who make them for Porsche. It's costing me £250 all in (I'm not doing it through the insurance).

 

[vitesse]

Steve,
Are John/Danny doing the bodywork or have they got someone else in to do it?Didn't you have some work done on that rear wing before?.Seems to me that anyone with a 964 should regularly remove both rear light units-both headlight rims & headlamps-the rear section of the front under wing protectors & pressure wash all these areas plus the extreme rear inner corners of the rear wings.Treat any rust with Jenolite,twice then spray 3/4 coats of a zinc rich primer followed by top colour.Most of these places are out of sight anyway.

 

[gregmarshall]

As you may of heard Steve I'm removing the Tank and replacing my entire HVAC unit so I'm going to deal with my scuttle and n/s front wing - i'm expecting the same as you and I am probably going to need a repair section. Autofarm said they could sell me one for around £65.

I know what you're going through... been there with my SC.... big time

 

[gregmarshall]

after...

 

[polar964]

Hi Steve, out of interest do know whether your screen has ever previously been replaced?
Did you remove this one yourself?
Do you think this corrosion was caused previously by poor removal of the screen, thus damage to the recess before a new screen was fitted. Just like a chip, once that protection is broken the rust worm is in there.

Looking good now though hey! Cars in good hands with John and Danny.

 

[NormalNorm]

Hey Steve, great work, now all these bits that am sure is on the back of your mind, or been bugging you through time is now all sorted. Tick that off your list[]

Dont you dread the things that lurk underneath seals and in this case the rear light.

Show us the final finish on the rear light housing.

Norm

 

[Steve Brookes]

ORIGINAL: VITESSE
Steve,
Are John/Danny doing the bodywork or have they got someone else in to do it?Didn't you have some work done on that rear wing before?.

Yes and Yes Colin. It's obvious now to me that the previous body shop only made it cosmetically good and never treated the root cause. Although not bodywork specialists J&D are used to panel replacement so will make sure it's right for me this time.

ORIGINAL: polar964

Hi Steve, out of interest do know whether your screen has ever previously been replaced?
Did you remove this one yourself?
Do you think this corrosion was caused previously by poor removal of the screen, thus damage to the recess before a new screen was fitted. Just like a chip, once that protection is broken the rust worm is in there.

Looking good now though hey! Cars in good hands with John and Danny.

There's no record of it being replaced but there was a lot of black silicone underneath which suggests it has (apparently any glue or sealant shouldn't be needed). Whether that has caused the rust is difficult to say especially since we all know that the screen is a well known problem on 964s and 993s. Russ removed it and will be re-fitting (you'll know him from Rennlist runs).

 

[Steve Brookes]

ORIGINAL: NormalNorm
Show us the final finish on the rear light housing.

Norm

Will do. Interestingly 9M had a spare quarter which they gave us (at a good price) to use. The car will now have some 964RS dna in it because that's what it came off! []

 

[Steve Brookes]

Update: The rear cross member has now been repaired, the rusty part of the quarter cut off and the replacement grafted on. Still a fair bit of work yet to do to get it ready for painting and the inside of the quarter needs under sealing but very pleased with the results so far. []

 

[mcgc0]

You sure it's on straight Steve.. []

Is that a pair of Conti's you have? And did you need to get any wing struts 'cos these things seem to turn to rust dust first contact with water!

 

[vitesse]

Looking good,Steve-take no notice of Marcus-he admits to giving up real engineering some years ago-so he's no longer on the level.
Why not have the whole car purple?

 

[Steve Brookes]

ORIGINAL: mcgc0

You sure it's on straight Steve.. []

Is that a pair of Conti's you have? And did you need to get any wing struts 'cos these things seem to turn to rust dust first contact with water!

Yep, it's just the rest of the car that is bent. []

Not two but four Contis on there Marcus. You've only seen it with the other wheels on that have Toyo R888s. I've also got a set of wheels with Mich Cups on aswell. Wing struts are fine because I'd already replaced those with the Harradine after market ones.

ORIGINAL: VITESSE

Why not have the whole car purple?

I was thinking that too! []

 

[colin129]

ORIGINAL: Steve Brookes


There's no record of it being replaced but there was a lot of black silicone underneath which suggests it has (apparently any glue or sealant shouldn't be needed). Whether that has caused the rust is difficult to say especially since we all know that the screen is a well known problem on 964s and 993s. Russ removed it and will be re-fitting (you'll know him from Rennlist runs).

Mine's in for some long overdue work, both front & rear screens out and also that nasty, rusty, hole on the panel behind the nearside door. No mention of any horror stories from Langley Autocraft, who are dealing with the repair, although it is taking twice as long as predicted.

This sealant, when I first had my car it was all wet inside and I had a load of sealant put round the screens front & rear which cured the problem. When I mentioned this to Langley, worried that the leaks may come back following repair, they said that the reason it was leaking was that, obviously, the screen surround is full of holes! Once the screens openings are properly repaired, there won't be any leaks.

Not only did they mange to take both front & rear screens out without damaging them, but they saved the rubbers too giving me enough budget left to paint the bonnet too!

I'm only having the serious stuff sorted at this visit, there are one or 2 other bits that will need looking at, but that will be for another time...

 

[Steve Brookes]

Welcome to the renovation thread Colin! Hope it all goes well and feel free to post any pics of work on yours too.

 

[NormalNorm]

Coming on strong Steve, great workmanship from the guys. The car will look spot on after the New Year once its all painted, ready for the new season. Keep those pics coming, I like pictures[]

 

[andrew_churcher]

good work Boxsey.....i assume the GT3 is on hold then? []