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Rust

An interesting Post.
I too purchased my first 944 3 years ago based (in no small part) on the often praised galvanised body.
Since then I have found several patches on the sills. These all looked to have been caused by poor jack placement during its 20 odd years. The stonechip protection has been disturbed and, in places, the crucial drain hole slots have been deformed causing condensation to build up. Generally however (on that car) I was impressed by the lack of any serious rust from a car that rolled off the production line in the early eighties.

My biggest experience of rust though has been on my track car project.
I picked up an '84 donor car early last year, mainly for the fact it had the rare non sunroof shell and was free from accident damage.
The project being to completely strip and rebuild the car as a fairly std but lightweight (for a 944) track car.
On initial inspection the sills and wheel arches looked to have patches of rust but nothing too major, I thought. It wasn't till I got the car home and started stripping it down for a closer inspection that it seemed the patches were only the tip of the iceberg.
It must be said that this car is, in my experience, a particularly poor example [:eek:] that has seen many years of neglect through its life.
But hopefully I have several pictures taken as the project progresses that may be of interest, if only to see evidence of some possible, "˜worst case' spots for rust on these cars and work carried out to fix them.

In order to post pictures do I need to upload them to a website?
 
Car age/model: 1990 S2 Cabriolet
Have you taken any preventative measures eg waxoyled: No, but I will be doing soon
Do you have any corrosion, and where: None now, but until about a month ago there was some rust at the bottom of the drivers side wing behind the wheel, some down the drivers side sill, and a little surface rust around the rear wheel arches. Oddly nothing on the Passenger side. I also had two small bubbles on the top of the drivers door where the glass enters - looked like someone had been daft with the touchup paint, but it was actually rusted through underneath.
Have you had this treated: Yes - rust cut out, metal welded in, treated and resprayed.
What was the approximate cost and extent of work: Ouch.
When, and is there any sign of a problem recurring: There'd better not be any sign of it returning yet!!
 
The cab especially seems to be prone to hamfisted removal and refitting of the window external seal on the door. The metal clips easily cut through the paint and galvanising and then the door starts to rust in blobs along its top edge.

Jonny: You can add one pic of up to 200kb in size per post without uploading to a hosting service.
 
ORIGINAL: Fen
The cab especially seems to be prone to hamfisted removal and refitting of the window external seal on the door. The metal clips easily cut through the paint and galvanising and then the door starts to rust in blobs along its top edge.
That seems likely to be the cause - something for me to look out for if ever I have to mess about there. Cheers!
 
Car age/model:
1987 944S

Have you taken any preventative measures eg waxoyled:
Sills and arches were waxoyled when they were repaired in 2005.

Do you have any corrosion, and where:
Yes, rear arch lips and N/S bottom of rear arch. Also very bottom of N/S front arch sill.

Have you had this treated:
I have previously had both sills (N/S and O/S) repaired in 2005.

What was the approximate cost and extent of work:
Cost was around £1000 and both sills were stripped, welded and repainted.

When, and is there any sign of a problem recurring:

Yes [:mad:] [:eek:] [:(] started this autumn, see above "Do you have any corrosion..."

Previous thread detailing the extent of the work already carried out.... http://www.porscheclubgbforum.com/tm.asp?m=143432&mpage=2&key=sill%2Crepair&#143875

Regards

Dave K.

 
Dave
This is worrying considering the magnificent efforts that you went to in order to cure your rust problems.[&o]
It just goes to show how hard it is to keep on top of these things.
Alan
 
Hmm. It worries me too - I've just had the bodywork on my S2 sorted out. It wasn't as bad as yours, but I would hate to see the tinworms feeding on my sills anytime within the next few years. Something else to worry about!!
 
Got mine done on both sills (very bad with holes) and the front wings behind the wheels last Oct by Porscha in the Midlands with their custom made sills, waxoil, paint and powder blasted finish at a cost £1k. Job well done. I have since removed the plastic sills which many reckon is the main cause of rusts. The S2 now actually looks better without the side plastic sills.

Charles
 

ORIGINAL: andymorris

The rust issues on my S2 are, bottom of front wings behind the wheels both sides, Sills both sides and around the little lights above the number plate. I should have a quote from a bodyshop in the next day or so.

My Indie got a price for the work from their guys somewhere in the region of £600-750. (depending on what they find)
 
ORIGINAL: Hilux

Even the bottom corners of the front wings were 100% solid until I cut them off.

[:eek:][:eek:]

What for? To fit the 968 sill skirts??

Exactly.

Charles - don't you see all sorts of unappealing gubbins like jacking pointsn hanging down under the sill when you remove the trims, especially on a white car?
 
Fen,

Yes a bit but only if you look at it lying horizontally [8|]. I think the S2 sits low enough to avoid amateur concourse inspection [;)].

Charles
 
I've got a -85/5(or 86 as i recently found out)..

The worst bit where i had rust - sills..and that failed her on MOT the first time last month..so something had to be done - i took her in to a local welder..he cut off the old sills from the gap where front wing ends to all the way to back and replaced them..you can hardly notice the differene..that cost me £130 inc. VAT..now all i have to do is get a pair of side skirts ang fit em on..

Other that that just some surface rust on
NS wing..
Pop-up lights' edges..
Rear number plate lights' edges..
Some small thingies here and there(grown out of stone chips)..

And of course underneath..but nothing too serious considering her age..


Just sanded some of it off last weekend and will carry on this weekend..i'll just spray it temporarily with aerosol for now as there's not much time left before i'll get her re-sprayed..
 
Car age/model:
1984 944
140k
Condition - shoddy

Have you taken any preventative measures eg waxoyled:
Car Purchased last year - then stripped down to bare shell

Do you have any corrosion, and where:
Rear wheel arch back section.
Both sill sections near the jacking points
Rear section of both front wheel arches where the wing meets the body
Driver and passenger foot-wells!?
Number Plate light openings

Have you had this treated:
Stuck the car in the garage, rolled my sleeves up, borrowed a friends welder and set about learning how to sort it out.

What was the approximate cost and extent of work:
Paint and materials £100
Donor Shell £150
Sliced fingers, bruised knuckles and rust in eyes/ears...., priceless[&:]

When, and is there any sign of a problem recurring:

Ask me next winter when its on the road.

Rear wheel arch back section

EF65AF2846EF4AEC94DC03488C995B76.jpg
 
All rust was removed completely where possible.
Any remaining specs were treated with inhibitor and Acid Etch Primer
Weld-through zinc rich primer was applied to bare metal area requiring welding

12C22CEF223246A7A68C88C84E8AB588.jpg
 

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