964 C2 - Rolling Resto

[rhd racer]

No problem Raymond. Payment by Rioja!!

Parts have arrived so will collect shortly. Let’s hold off putting out the bunting for a while yet....

[wadsworthi]

Looks like it has been snowing on your harness plug in the last picture! Good perseverance Wayne despite the loss of blood and most importantly fingers crossed no more burnt wiring!!

[rhd racer]

Yes, that was the residue from grinding off the old carrier for 2 of the small connectors that I was unable to remove.



New parts collected



The refit was straight forward. Refit the carrier to the holder



Gave the fuse box itself a good clean whilst I was in there (hoping to never have to remove again!)



Then refit. It is a little awkward, but to be honest getting the nuts back on is more of a pain with sausage fingers!



Then feed the wiring into the slots - this really is a pain



And then bolt in the relays carriers, fit the new relay and reconnect all the main engine connectors. The spare relay holder on the far right is for cars with air con, so unused on mine.



Then fit the new ballast resistor. You can see most of the insulation had perished away on my old one, and the clips were so worn it did not seat in the trunking at all, only being held by gravity....



Then refit the temp sensor and trunking . Job done!



So with some trepidation and a little excitement I reconnected the battery...ignition on, no engine fan. Damn

Then I remembered I had removed the fuse (doh!) because there were a number of reports of fuses looking ok but being knackered after this type of fault. So, fuse replaced, ignition on and whoosh - a noise I have never heard before, the engine fan working!! No smoke, no burning, result.

Now the real test, return the fan up to 4 on fully cold and it worked. Increase the temp past 18, and keep going, dash blowers still on, this is a first (!) all the way up to full hot and still on. The engine fan also kicked into high gear too, and then returned to slow speed with the dash fan down to 2.

Finally a test of the defrost button which overrides all functions and makes the engine blower go to high speed and dash fans to 4. That worked too!

Then ignition off and the engine fan did not cut out, so I disconnected the battery to regroup....

A quick search suggests that the fan is designed to run on if the engine is really hot (but I had not started the car). Failure to stop is caused by a failure of the temp sensor on the top of the duct, a £40 part. However, I reconnected the battery, retested everything and ran the car up and all functions worked and the fan stopped with ignition off as it should. So I need to keep an eye on this, but can only assume it was a bit excited about running after all this time....

So appears I have somehow avoided a £1000 rebuild of my HVAC unit, hoorah! I have left the battery off just to be doubly safe until I can test it all again, but Christmas beckons so am needed elsewhere.

However, a huge result





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[PeterK]

Well done, that man

[DustyM]

Nice one. Satisfying isn't it.

[rhd racer]

Thanks chaps

And thanks to Jonny Hart too for being on standby with another piece of the puzzle if it was required

[72911E]

Great result and perseverance

[rhd racer]

Many thanks. Finally test today, I ran the car up to full temp whilst cleaning the cars. When I turned the ignition off the fan kept running as it should, to cool the engine by blowing away residua warm air. This can go on for 20 minutes...

After 10 minutes it was still going, which I thought was a bit OTT for having run up without driving anywhere, so I retired for a brew resigned to ordering a temp sensor and hoping that fixes it. A couple of minutes later I returned to the garage, brew in hand, and the fans had gone off! So I think they ran for about 15 minutes or so, which I take as a passed test and properly attached the battery again and am ready to move on to the next stage of the interior.

[rhd racer]

Two for the price of one day today...

Two fixes, one part (albeit not cheap)

Two injuries from one event....awesome

964 steering columns of a certin age suffer a couple of issues;

1. Failure to cancel indicators after making a turn
2. Burning out, leading to failure of indicators, flashers, both or a combination of each

Well, as you might come to expect, my car was suffering from both! Initially, I thought that failure 1 might be the Momo wheel and boss (remember I have not driven with the standard wheel). A bit of research suggest this was duff info, and that the small plastic pin that gets collected by the wheel to cancel the indicators fails. So, ithout being able to check with the wheel on, I was hoping this to be true.

But the reason for my replacing the stalks was failure 2, because when putting the indicators on with the lights on made the lights got out 10% of the time, and with main beam on, 100% of the time! Basically, the stalk was frazzled. The reason for this is, like VW stalks for years and for reasons which defy common sense, the stalks take all the load for the current. Instead of being a low load trigger for a relay, they take the full headlight load (for example) and as a consequence have an adjusted life-span.

The task itself is very straight forward and probably took only 30 mins end to end. Obviously the steering wheel needed to be marked in place, but having a yellow marker at 12 o'clock makes that fairly easy! In fact, the 964 column shroud and levers fit in exaclty the same way as the Boxster.

Pop off the horn ring, steering wheel nut is 24mm on later cars



This is the new part, direct from Porsche, showing the indicator cancelation tab in black, at 9 o'clock



And then the existing one, showing a failure by the tab coing out at 9 o'clock when the indicator is used, and then settling at a more relaxed 8 o'clock for left, and 10 o'clock for right. Basically something broken in the mechanism meaning it just kind of went floppy and failed to work.......





6 screw secure the cowl in 2 parts - 2 at the side, 4 in front



The connections just pull off the rear



And the stalks are removed by an 8mm clamp around the column, and then this is what is left



Then you need to transfer the horn earth, which simply unclips and drops into the new column switch



Refitting, as they say, is the opposite of removal, so not really picture worthy. When reconnecting the battery, I was pleased to see that issue 2 was immediately fixed, and I could indicate with main beam on.



There is another phase to this fix, which is to fit some relays so the stalk wires become trigger wires only and don't take the load, but I need to order a couple of relays to do this.

I am also pleased to say that issue 1 was also fixed, and we now have cancelling indicators again!

The day then took a dark turn, when as I was clearing up a bit, I decided to put some old Boxster airbags in my garage loft. They were in an open box, and half way up the ladder I must have tipped the box and the first airbag fell out of the box and the metal mounting bracket got me square on the top of the head. I managed to catch it on my chest and stop it falling directly on the Boxster below. As I bent over in some pain, I must have tipped the box again (dick-head!) and the second one fell out and hit me in the same place.

Blood was lost

Rude words were said

Boxster was saved....

The offending items weigh at least 5kgs each

[rhd racer]

My noggin....



Not an easy selfie to take, I can tell you! On the plus side, as a man closer to 50 than 45, no grey or bald patch has to be a win!


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[jwhillracer]

Was your friendly medical adviser able to patch you up without too much p155-taking and laughter?

JW

[rhd racer]

On an afternoon I should not have probably been operating any heavy machinery, I decided to have a go at fixing the rust dash mount. First off, I drilled out the screw to release the remains of the steel mount left behind when the dash came out



This was what was left



You can see that it has a form to it that needed a bit of work, and feeling under par I went looking or something that might fit the bill. It did cross my mind to rust treat and refit given the low impact role it plays, but I dont really see the point in doing a resto and finding something knackered and ignoring it. Luckily, I dont throw anything away, and had a random Boxster bracket that would do.









With really no effort it was looking quite good, but too small and the bonding area therefore reduced. I then found another panle, the same as the first, that I had used for something else, but the cuts would allow me to extend the piece already 'made'



A rough cut and it looked pretty good



So, I welded them together (ignore the hole at the top of the shot, caused by the welder being turned up too high, this was filled later)



Then with a little fettling, it looked ok against the original...



Then fitted to the dash, the L shaed section kind of loops into the foam dash, presumably to apply greater fixing strength, we have something to work with that I have now painted (hole to be drilled later)



Whilst playing with the dash I noticed some damage not seen before (it is on the passenger side). Not sure whether to ignore, or try and fix where the dash has 'bubbled'...my inclination is to leave as it is and change to black - it will likely show up even less in black





There was also a bullet connector poking out of the top of the dash which I traced to an antenna booster unit, so I made this safe by heat shrinking and tying out of the way.



I am also expecting to do the windscreen corners when I repaint, but the dash seems to have taken a bit of a hammering too, so this will need addressing too...



I guess I need to make sure the dash top goes on in an easily removable way!!!

[rhd racer]

Was your friendly medical adviser able to patch you up without too much p155-taking and laughter?

JW

Ha, what do you think JW?!!

Anyone that lives with someone in the medical profession knows that all the compassion, care, sympathy etc is exhausted in the day job and I just get called out for being the pillock I am !!

[wadsworthi]

My noggin....



Not an easy selfie to take, I can tell you! On the plus side, as a man closer to 50 than 45, no grey or bald patch has to be a win!


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That looks nasty Wayne! I think you need to read the Motorsport UK health and safety garage guide, paying particular attention to the wearing of safety helmets. Good job you have resisted the temptation to have all your hair removed like some of us as it does at least cushion the impact!

Keep up the good work.

[rhd racer]

My noggin....



Not an easy selfie to take, I can tell you! On the plus side, as a man closer to 50 than 45, no grey or bald patch has to be a win!


Sent from my iPhone using Tapatalk

That looks nasty Wayne! I think you need to read the Motorsport UK health and safety garage guide, paying particular attention to the wearing of safety helmets. Good job you have resisted the temptation to have all your hair removed like some of us as it does at least cushion the impact!

Keep up the good work.

My risk assessments usually focus on damage to the cars rather than me, as this thread proves Ian!

I ruminated for a short period on what to use for sticking my new painted bracket to the dash and settled on Sikoflex. It is an adhesive / sealant used on Motorhomes etc and all my previous interactions suggest that it sticks like wotsit to a blanket and attached everything in its path!

And so it was



Clamped in place. I tried some elaborate pads to reduce the impact of the clamps but these just kept sliding off, so it is all on my office now curing and we will see where we are tomorrow!



I then started work on the interior. A cautious start, because I don’t want to rip it all out and then I can’t have the alarm fitted (Covid etc). So I thought I would start on the rear parcel shelf, which I have already covered in grey but a change of plans means it needs to go black. I bought some vinyl on eBay for the door panels and the rear shelf, so with the former currently a no-show decided to do the shelf. Stripped out and ready to go I need to deal with hiding the sub, so a piece of covered wood will do it





Anyhow, my plan was to cover over what I had done before. The adhesive was ace, it stuck fabric to fabric but my methodology was flawed and I made a proper Horlicks of it and had to take it all off. Luckily I bought extra. No pics, it was too shameful!


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