964 C2 - Rolling Resto

[rhd racer]

Must also share this bought at the Silverstone Classic. I want to put it in the downstairs loo but am not allowed as the girls are too young (or their friends are) so currently consigned to the garage.

Made me laugh out loud




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[hot66]

might get some of that floor paint .. alll mine has lifted now after 10 years or so & its now just dusty bare cement

[Dammit]

You have no idea how many times this thread has me checking ebay for a bargain 964.

[rhd racer]

You have no idea how many times this thread has me checking ebay for a bargain 964.

Ha, yep I was lucky, or unlucky depending on your perspective. I bought well which made it viable but only with me doing everything myself and it taking a lot of time, effort and money. I think I will end up on the right side of things = below an entry level less desirable C4 coupe or C2 Targa, but the difference being I will have rebuilt everything except the body, and they will have money to spend to get to the same condition. In some respects, getting a complete dog is a good idea because then you know everything is done, and as you will have seen, replacing just one suspension or brake part for example might lead to more; small jobs become big ones. The trouble is, today most people think that a 964 in any condition starts at £40k. I know of one at the moment, that was born red and is now pink, been in a garage for 15 years, smokes like nothing else and needs everything to recommission. The price, you guessed it...

So before the next step of the rebuild I wanted to stop it winking - not so easy, the headlamp did not fit. The bucket was still too tight to get it aligned correctly to the wing, making me realise why the flap in the bracket was open to the elements. So I removed the new glass I had put in, and reformed with a big indent for the adjuster unit and then moved on....



This was only attempt 3. Poxy thing....

[rhd racer]

With the mechanical work all pretty much done, I have been hankering for a change of scene. There is lots to address;

- Poor electrics, no horn, no central locking, some dash lights and instruments not lighting correctly hiding problems
- Interior smells like a dead dog
- Dirty carpets / seats / not tilting correctly
- Sunroof seal poorly fitted, and poss leaking
- 2 speaker stereo. No hands free, no DAB, not up to business trips
- Ignition switch failing
- Dodgy steering wheel
- Old redundant alarm

Quite a bit then.

So ,seats out. Passenger side looked sensible



The dynomat on the floor confused, and then I remembered this was the bit of damaged floor, so is probably a way of concealing it from the inside. One for another day, and the repaint time



Drivers side next. Removing the seat was interesting, it was rocking already....



It turned out this was because the steel sliding captive nut that should slide down into the runner was missing, so a screw headed bolt and nut was used, only there is no access to do the nut up. See below for trying to undo the two threads that it was held on by..nice



The passenger side turned out to be the wet side. Broken glass from a prior break in, a bunch of wire, some bare, some literally cut and grounding on the floor.

[rhd racer]

So I started with what I knew needed to come out, and that was the old siren in the engine bay.



The old seat back closing panel was not nicely fitted



This revealed very damaged heat insulation in the cabin side of the engine bay





With the rear shelf removed (undo seat belts, then just 2 screws and the speaker connections) I could remove the OSR panel and feed the wiring through. Luckily, this immediately got rid of those bare red wires in the earlier pic, which I could cut out. I could then identify that the bug white block was the aftermarket alarm loom, so I could also eliminate that bare black wire which looked like it had been trapped in the seat and ripped in two.

Whilst there, I decided to delete the rear wiper. I was in two minds about this, but it didn't work anyway so out it went. I have ordered a proper blank, but when I paint the car I will fit an RS screen.



So at this point I put the battery back in, and made some covers to prevent earthing on the body (the one over the earth so I can disconnect the terminal and then sit the earth lead on the cover, so it cannot create a contact and make it live again)



I then tested the central locking out of curiosity and it worked! So stripping out the crud, and that black lead either made a short (though less likely as no fuses blown) or more likely making the central locking circuit break was all that it took. Result

So then moving onto the steering wheel, I removed the airbag first (after disconnecting the battery for over half an hour). It was loose, which was no surprise. Given the dash lights, it may not have been activated. So then wheel removed and then the plastic bearing which contains the horn ring, you replace the lot with this OE part from a 928



Then mocked up with the boss



Then refitting the cowl revealed that the boss is a bit larger than OE.



A quick search found a thread on Rennlist suggesting a can of Coke wrapped in sandpaper but I had a new roll of course paper in stock.



This took too long, so I used my belt sander then finished it by hand. I had to be careful though.



With clearance all round I could fit the wheel



Oh, and the horn now works. Tick

[rhd racer]

Before I started on the interior, I took some pics of the redundant kit

Remember these every time you got in your GTI?



And the OE amp under the driver's seat. 4 x 20w - wowzers....



So I set to cleaning the seats. I know there are proper ways of doing things, but in most cases I default to Jiff, (Cif for the young folk) because if that doesn't do it, nothing will. (Interior restorers roll eyes!). A couple of half and half shots





They actually cleaned up really well. So I then sponged them off, let them dry and used Autoglym stuff on them to soften back up. I know the driver's seat is still pretty worn, and I could make them like new for £100, but TBH it is 180k mile car and clean is good enough until I go for a full re-upholster.



I then replaced the cassette storage bin with a plain one more suitable for a phone ipod



And cleaned up the rear seats, treated them, then wet and dried all the carpets which came out fairly well given the starting point (they are Southbound replacements). Not my choice colour wise, but again ok for now.





And then rust treated and painted the seat runners that were making orange streaks on the carpet





Incidentally, I think the leak is coming from the rear screen as there seems to be lots of that clear 'leak finding' solution on the inside of the seal in various spots.

[rhd racer]

Onto the stereo install.

I am a huge music fan, listen all day at work when not in audio meetings and in the garage. Whilst I am sure the G pipe sound will be intoxicating on weekend drives, it might drone on the odd commute at motorway speeds so I want to have options. That means DAB, aux input for my ipod and hands-free. Nav a bonus. The OE one that Porsche sell is just not a viable option financially, and I did not like the ones with a huge screen either, so disgruntled I looked at speakers instead.

So there is talk of under seat subs, a phenomenon I am not used to. My first beetle had two 12" organ speakers before I could afford subs, and my other beetles / golfs a twin 12" sub box with a dedicated amp. I researched these and a lot of 964 forum talk suggested they would not work and most people put them where I want my daughters feet to go. Undeterred, I bought one anyway, but with a plan B in my mind. I landed on this as the smallest I could find



For less than £100 delivered, in a small space 160W max will be more than plenty. I think it could actually fit in place of the original amp, but the loom in the bottom left of the pic is the problem, as it would need to occupy the space right up to the sill to fit



The passenger side has more space, but the seat is lower, so the problem just moves



But, I have my eye on that ill-fitting rear seat, the space behind it and 50mm of rotten sound deadening on top of that...

[hot66]

On the rear glass... not sure on part numbers etc, but my car came factory with no rear wiper so has the rear screen with no hole.

Not sure if still available or wether it’s the same as the RS ( Rs was meant to be thinner but still had defrost mesh even if it might not be connected).

I gather the rear screen available for the RS from Porsche has no defrosting mesh these days even though the original had it it.

Would be intersting to know what is available these days when you get round to looking

[hot66]

If during your resto you discover any replacement bulb holders for the rear lights ... let me know . I’m after a rear tail light bulb holder wether Porsche or from some other manufacturers

[rhd racer]

Thanks James, I will commit that rear screen info to memory for when I get there. The rear demist is not working, so another thing for me to investigate. I was not aware some non RS models came without w/w.

I have another parts delivery coming today which should necessitate removing the rear bumper and changing the rear deflector whilst I am there. I will take a look at the rear lights as I know they are suffering water ingress from those crumpled inner arch panels. On the 914 I had to fit new 21w bulb holders and I think bought some of those Hella Land Rover type bullet units, but will let you know what I think.

Cheers

[hot66]

Quick pic of mine just taken at the mot station

[DustyM]

A very late 3.2 Carrera uses the 964 type rubber but still had the rear wiper on the engine lid so that screen would be a heated screen with no hole


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[rhd racer]

Thanks Jon, that's very helpful.

Have just realised I have not updated for 2 months, suggesting I haven't done anything. I have been distracted by Christmas etc, but also race prep for next year on the Boxster (gearbox out, LSD shimming, driveshaft upgrade) and buying a new motorhome and kitting the garage out for race weekends (and fitting air suspension to it).

However, the 964 is coming along, and Angus and I are talking about dates to marry the engine and body - I just need to priortise getting the Boxster to him first for cam timing before going off to the rolling road for a remap as we are allowed a power increase this year.

So, the 964....wiper delete first. You can see the original washer was completely mis-shaped and possible the cause of the leak







The delete blank is a really nicely made thing - it is just somewhat awkward to fit on your own, so I had to support it from the underside and screw in from the top, but it works really well and a basic test suggests it is water tight







I then finally got the headlight fitted, albeit after some gentle reshaping of the screw hole and adding a washer because the rim had been damaged by the large bolt and over-tightening over several years.





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I then fixed the coat hook too

[rhd racer]

I know stereo installs aren't the norm in a DDK build thread, but I thought it might be of interest to some.

For the hidden sub I marked out where I wanted it to sit, and then cut out all the damaged sound deadening











And then drilled blind for the rivnuts, luckily I found a cavity for the bottom one (this is from lying under the car looking up at the bulkhead between engine and box). The top ones is behind the engine bay sound deadening.





So with the sub mounted, all hidden from view it now just needs removing, a thin sheet of sound deadening applied behind (I have something a bit like Dynomat for this) and then I will run the leads. However, I have been exploring DAB options and have bought an aerial which I will wire at the same time, as they can use the same switched feed.