964 C2 - Rolling Resto

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Re: 964 C2 - Rolling Resto

Post by rhd racer »

Having run out of the satin top coat and binder, leaving one seat unfinished, I set about the carpets. This is another new job for me, and despite restoring (-ish) or modifying lots of cars in the past, they have always been rubber mat jobs (Beetles) or 'no carpet required' - being competition cars, rather than a Phil Collins album!

Anyhow, the carpet set is the Lakewell one, very lightweight, which is a bonus, and with instructions that leave something to be desired. Imagine 5 printed pages of thumbnails and you get the idea. You can barely make out what section of the car they are on, let alone what they are doing. So, I threw that in the recycling and set about working it out myself. I laid them in the car first, some bits obvious, some not

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I knew there were a few things to be very careful about;

1. Order of fitting, so that the seams always sit over the top of another section

2. Containing the contact adhesive to the parts of the car I want to cover!

3. Making sure that there was always sufficient overlap for the next piece or pieces, so therefore I needed the next two or 3 pieces to hand to make sure I could check before it is stuck down

I figured that the centre tunnel was the best place to start - it is the only piece that comes with a hole in it for the gearstick, but is also one of the most complex because there are lots of brackets welded to the floor which needed slots cut out for.

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I considered a couple of ways of doing it - measuring between a known point and the first bracket, flipping the carpet over and cutting, but I am not convinced the tunnel is exactly a mirror image side by side, and therefore what appears to be a square cut in the carpet could be on the wonk in situ....so I marked with some tape, removed and cut (and it did sort of proved the theory as it was not whatt I would have expected if using the former method. I then set about the 2nd bracket in the same way

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Once done, I glued the nearest section to me first, to locate it where I needed it to be, then bolted the console mounts in place to secure it, and then glued the sides. This ensured nothing could move as I worked. I found out early on that the challenge to removing the 1" thick sound pad is a less sympathetic shape to glue to, and creates a bit of excess carpet too.

Console was easy though

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The 2nd section of the tunnel is next, due to an overlapping seam. This bit needed cutting out for the handbrake, and there was a chalk line on the back of the carpet as a guide...

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However, I was a little concerned that having taken out the sound deadening, I could end up in a slightly different place than an original refit, so measured over and over until I was happy with my more conservative cuts...

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When I positioned this and the next piece in place, I was slightly worried about the space age shiny silver sound deadening showing through by the rear seat hinge, so I made a small piece to glue into place around this section

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This would make it harder to refit the seats as I found out later!!

One thing in the back of my mind was the gap between console and tunnel, by the use of less dense sound deadening, so I added a bit of 1" foam. This is is limited to one section only, and not on the floor, as I didn't want another moisture trap (although I traced the leak to the rear window corners, which for now I have arrested with a tiny smear of clear silicone sealant).

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And then glued the next section in, my smaller cut out proving to be the right decision

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The rear footwell sections took some position and a test fit of the rear quarter trim panels to work out where they go. I started by gluing only the most forward edge, because it needs to be tucked under the trim lip.

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These pieces needed some cutting to get it to form correctly, but it worked out ok. I learned from difficult experience that cutting the seat belt holes is best done before glued, but I was to repeat this disaster several times later, so hopefully someone will learn from taking my advice where I seemingly didn't!! I could then put the final rear section in (seamed) that forms the rear of the seat squabs. What really surprised my is how the carpet could be carefully manipulated to grab with a curved section and take that form, it is completely unlike covering a door panel in fabric, which relies on pulling things tight. This is the reverse, and feels a bit odd at first.

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and then the upright footwell into seat base sections (seamed again). I found that using masking tape kept the glue of the sections I wanted to keep clean. I didnt always work, as pressing the carpet in tight shrinks it from the original position, so keep the white spirit handy! I also found a couple of pen marks helped me ensure that I had the coverage for the next section, as in parts only an inch or so in the wrong place would leave you with exposed floor

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I could then ft the reat card and capping trim - really pleased with the contrast of materials and the flow from front to rear

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93 964 C2
99 Boxster 2.5 > 2.7 hill climber

71 914/6 3.0 - gone

'You see Paul, hill climbing is like making love to a beautiful woman. You get your motor running, check your fluids, hang on tight and WHOA..30 seconds later it's all over!' Swiss Tony
rhd racer
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Re: 964 C2 - Rolling Resto

Post by rhd racer »

I then masked up the rear seats and fitted the seat back carpet

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I won't lie, the rear seats burned hours.....

1. The locking mechanisms would not work. This was partly the extra layer of carpet making it difficult to fit the seat onto the pin it sits on. I needed to use a drift and hammer to get them far enough onto the pin, and then a space at the bolt end to keep it there. Got there in the end, but took hours of messing about
2. The elastic strap that pulls the backrest carpet out of the way when you raise the seats. You know how on car restoration programmes they dismantle cars, put bits in bags, label them, do a diagram if needed....who does that? Well, everyone should, because it would have saved me several hours...

Turned out ok though

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The foam section between the seats really feels like the right decision now, as the armrest between the two.

I think the dog will be very happy there

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Onto today, I started the sills, and got one side done at least. The lack of heacy padding means you can see where the loom runs etc, but hey, you cant have everything. Oh, and I forgot to cut the whol for the seat belt again.

And the strange dangling situation is my realising that I did not paint the seat belt brackets when the car was empty, and now everything looks so good I couldn't put them back in like that.

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The side trims are a cock up. 964's obviously have crossover years, and mine had plastic covers with clips, and it was all shot, so I ordered new trims (from my OPC) and new clips as part of an order from D911. When I fitted up the trims they are the early ones, that fit with self tappers! So I am going to drill the sills tomorrow and fit the ones I have....

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The lesson on the seats was the dye sticks sections together, so when you open up a seam (like hovering the crack in a seat) it tears and leaves a section of the original colour. This happened on the sides of the squabs, and at the point that the backrest and squab meets.

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I didn't want the seats to make a creak every time I sit in them, and to deteriorate over time, so I painstaking held open sections with my hand, painted, dried with the heat gun, burned my hand, and repeat. Over and over I burned my hands to get them so they are covered in every crack, and then gave them a final coat of the satin sealant, and fitted the trim with new screws.

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Finally a seat to be proud of!
93 964 C2
99 Boxster 2.5 > 2.7 hill climber

71 914/6 3.0 - gone

'You see Paul, hill climbing is like making love to a beautiful woman. You get your motor running, check your fluids, hang on tight and WHOA..30 seconds later it's all over!' Swiss Tony
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KS
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Re: 964 C2 - Rolling Resto

Post by KS »

Very impressed with the seats!

Agree with your comments about Lakewell's instructions! Great carpets and nice company to deal with, but the instructions are indeed useless. There was an extra piece in the 914 kit, which I couldn't fathom out – turns out it was to suit the early cars with fixed passenger seats, but their diagrams didn't make that clear. A nice touch, though, was their supplying a length of extra carpet so you could cover section sunder the seats, if you so desired (something the factory failed to do).

Anyway, back to your 964...
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964RS
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Re: 964 C2 - Rolling Resto

Post by 964RS »

Amazing transformation, you've put some work in and it looks so different now :thumbright: :thumbright: :thumbright:
----------------------------------------------------
Jason
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Re: 964 C2 - Rolling Resto

Post by rhd racer »

KS wrote:Very impressed with the seats!

Agree with your comments about Lakewell's instructions! Great carpets and nice company to deal with, but the instructions are indeed useless. There was an extra piece in the 914 kit, which I couldn't fathom out – turns out it was to suit the early cars with fixed passenger seats, but their diagrams didn't make that clear. A nice touch, though, was their supplying a length of extra carpet so you could cover section sunder the seats, if you so desired (something the factory failed to do).

Anyway, back to your 964...
:lol: Glad it’s not just me then! The dye is pretty forgiving, so touching in the bits that stuck together works ok, but diminishes the finish a tiny bit. I figure in odd hidden areas this is a compromise I can make, as long as when you look in the car it looks like an original black seat without subjecting it to a forensic examination I am happy!
964RS wrote:Amazing transformation, you've put some work in and it looks so different now :thumbright: :thumbright: :thumbright:
Cheers Jason...heading your way when finished :)
93 964 C2
99 Boxster 2.5 > 2.7 hill climber

71 914/6 3.0 - gone

'You see Paul, hill climbing is like making love to a beautiful woman. You get your motor running, check your fluids, hang on tight and WHOA..30 seconds later it's all over!' Swiss Tony
rhd racer
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Re: 964 C2 - Rolling Resto

Post by rhd racer »

It's been an emotional few days, burning the midnight oil to get it finished for an imaginary deadline in my head. I know we all do it, but I do it more than most..setting ridiculous deadlines that defy common sense. So with a chance to go and spanner for Angus at Donington yesterday, gave me a chance to a) feel a bit 'normal' again at a race meeting and b) what better chance to show him the transformation of the car that spent lockdown 1 in his workshop.

So this week I have been 'on one' as my wife would say...

First up fitting the new sill trims - these being the wrongs ones (I knew this) but for reasons I will explain later I had complete brain fade and drilled the sill to fit them (the 964 has plastic trims, secured by clips not screws).

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All was well until I tried the first screw and had gone slightly too small with my hole and the chinese grade steel of the screw gave way

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Luckily it came out easy enough with some mole grips

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I have since replaced all the screws with black ones. Then I covered the kick panels

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I then turned my attention back to my seats, which I noticed from the pictures uploaded, that the seat rails looked really rubbish (I guess that is the problem of making the seats so nice). So having painted those, I noticed the hinge sections looked rubbish too, so I painted again, very carefully, all the bits that let them down until satisfied

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Back to the kick panels I needed to make a little section of vinyl for the A post door shut which ripped when I tore it down

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And then realised that the driver's side kick panel rubbed the loom and clutch pipe, so I clearanced it in a way that cannot be seen

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Before trying to work out what the heck was going on with the pedal board carpet...

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Whatever orientation it just made no sense, and did not tie back to the original. I bought the carpet set cheap from ebay, so felt it rude to contact the manufacturer direct :lol: so did what I could to make good of the situation. I didn't understand what was going on , it could not be an auto carpet set as had provision for 3 pedals..maybe I will never know. Anyhow, I went hunting through the bin for offcuts of carpet, and decided that one of the storage bin carpet sections could be sacrificial....

Time for a Friday lunchtime 'field repair', with the clock ticking for a 10am Saturday departure, and no dash yet! So, made out of two pieces of carpet (to allow for a gap where the overmat sits on the footrest, I came up with this

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Which looks ok in the dark footwell. Good enough anyway.

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So onto the exciting stuff - first fit of the dash

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I then marked where the alarm sensors needed to go with tape, and then removed and drilled (the original movement sensors were on the rear shelf pointing forwards, the alarm guy said that either way the quarter lights were the weak point that needed protecting, so we agreed the dash corners was the best location for them

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Refitted, I just love the continuation of the flocking from dash to door

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I had resisted fitting the passenger side door capping because it has a slight blemish, but under my new timeline I could live with it!

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Refitted all the vents - much easier to fit than remove!

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before tackling the centre console, the sponge padding made up the gap perfectly

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At 10pm on Friday I gave up, leaving just the seats to fit (always fun) the next morning.
93 964 C2
99 Boxster 2.5 > 2.7 hill climber

71 914/6 3.0 - gone

'You see Paul, hill climbing is like making love to a beautiful woman. You get your motor running, check your fluids, hang on tight and WHOA..30 seconds later it's all over!' Swiss Tony
rhd racer
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Re: 964 C2 - Rolling Resto

Post by rhd racer »

So I made it, seats in and a new found respect for interior trimmers gained. A job it would take the professionals a week has take 3 months, but it has absolutely transformed the car, and I think suits both the current and future colours for the car...

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93 964 C2
99 Boxster 2.5 > 2.7 hill climber

71 914/6 3.0 - gone

'You see Paul, hill climbing is like making love to a beautiful woman. You get your motor running, check your fluids, hang on tight and WHOA..30 seconds later it's all over!' Swiss Tony
rhd racer
DDK 1st, 2nd and 3rd for me!
Posts: 2059
Joined: Wed Jun 23, 2004 9:47 pm
Location: Nottinghamshire

Re: 964 C2 - Rolling Resto

Post by rhd racer »

The sting in the tail is thus.....interior finished...check, car cleaned...check, battery charged...check, fuel...check.

Did it start? No

So I bailed and went in my daily. Had a great day, but the 964 remains in the garage with no angry noises coming from it. I changed the DME that morning but made no difference, and going through everything I have done, the only thing remaining is the fuel pump (a known weak spot in cars not often used) and maybe the 8 weeks or so since the alarm was fitted was enough time for it to fail. Hey ho, sometimes things are not meant to be, and our hobby can be a cruel mistress....

On the plus side, once that is changed there is literally nothing which has not been replaced, so I should be good to go for 250k miles apart from consumables!
93 964 C2
99 Boxster 2.5 > 2.7 hill climber

71 914/6 3.0 - gone

'You see Paul, hill climbing is like making love to a beautiful woman. You get your motor running, check your fluids, hang on tight and WHOA..30 seconds later it's all over!' Swiss Tony
rhd racer
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Re: 964 C2 - Rolling Resto

Post by rhd racer »

Oh, and I almost forgot. In my scattergun fashion of ordering things, not unpacking them, forgetting about them, today I had a big garage tidy up session and found the correct plastic sill trims and clips in a box. Brilliant :oops:
93 964 C2
99 Boxster 2.5 > 2.7 hill climber

71 914/6 3.0 - gone

'You see Paul, hill climbing is like making love to a beautiful woman. You get your motor running, check your fluids, hang on tight and WHOA..30 seconds later it's all over!' Swiss Tony
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hot66
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Re: 964 C2 - Rolling Resto

Post by hot66 »

Interior looks great 8)
James

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1993 964 C2
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Re: 964 C2 - Rolling Resto

Post by PeterK »

Great stuff :headbang:

Would you like to come & finish mine (just to save you from getting bored)
'79 Targa - restoration now mainly complete & being driven
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KS
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Re: 964 C2 - Rolling Resto

Post by KS »

Wow! What a transformation! :cheers:
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Re: 964 C2 - Rolling Resto

Post by rhd racer »

hot66 wrote:Interior looks great 8)
KS wrote:Wow! What a transformation! :cheers:
Thanks both
PeterK wrote:Great stuff :headbang:

Would you like to come & finish mine (just to save you from getting bored)
Cheers, give me a week or so to recover Peter!
93 964 C2
99 Boxster 2.5 > 2.7 hill climber

71 914/6 3.0 - gone

'You see Paul, hill climbing is like making love to a beautiful woman. You get your motor running, check your fluids, hang on tight and WHOA..30 seconds later it's all over!' Swiss Tony
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Re: 964 C2 - Rolling Resto

Post by 911hillclimber »

You MUST have a special supply of 'Patience Pills' in that garage!
I'm exhausted keeping up with the jobs big and small.
Love the upholstery transformation, so much more in keeping with the car as a whole imho.

Non-starter is a bit naff, but fixed soon no doubt if not already.

Great great thread Wayne for me and everyone else I'm sure, I appreciate the stark simplicity of my 911 now.

But what's next?
Peters fab Targa or a freshly painted shell from Gary... :wink:
73T 911 Coupe, road/hillclimber 3.2L
Lola t 492 / 3.2 hillclimb racer
Boxster 987 Gen II 2.9
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Re: 964 C2 - Rolling Resto

Post by rhd racer »

Thanks Graham. Not yet started, another patience tester.....

I have been working through non starting issues on another 964 and pretty sure we have isolated to the fuel pump, which are common for siezing. Without testing anything on mine, I took the plunge and ordered a couple of pumps - foolhardy / stupid (delete as appropriate), because I was certain it had to be that on the basis of;

a) It was started about 40 times by the alarm / immob installer, so couldn't be that
b) Cold start sensor already replaced
c) MAF tested and working
d) The only thing the car has done since point a) was sit, and have the interior put in, with no wiring jobs and minimal disturbance of anything

It had every hallmark of a seizure after 2 months sitting, and little in the prior 2 years.

Plus, I got a great deal. A genuine pump is c£500, which is a lot for something with a reputation for failing on low use cars. The cheapest non genuine pump is about £90, but I got two for this amount, delivered from Germany with no duty in a week. One to fit, one for the toolbox for next time. My logic suggested this made good sense.

Anyhow, I have been somewhat distracted by home jobs after a period of putting them off to work on cars, so was eagerly awaiting my parcel and did nothing further. Today they arrived - all good

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So tonight I got the car in the air and removed the cover for the pump, which is just in front of the passenger footwell. It is really tight in there, hence the connections are covered in rubber boots, nd eventually you can just about jiggle it out

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First up I turned on the ignition, but the pump did not prime as it should. So I checked for 12v and there was nothing. At this point I was starting to think my bargain fuel pumps were going to be moderately price paper weights! I changed the DME for the two that I have spare, with no change. I checked the fuses for the ECU and the DME, again no joy. I checked for current on terminal 30 at the DME and had 12 volts, so after a little research I made a jumper lead with a 5v in line fuse, so it permanently powers the pump and ignition circuit.

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Guess what, the pump ran! So the new ones are indeed consigned to paperweight duties! But it still didn't start....

So, with fuel eliminated I put a spark plug tester onto a lead and there is no spark either.

Sort of knowing the answer, I called Gus to kick it around and concluded that with the car not moving for 2 months, having no spark or feed for the DME suggests an immobiliser issue, be it of my doing (unplugging or disturbing something when doing the fit out) or a fitting issue. So I am going to call them tomorrow, the saga continues.....
93 964 C2
99 Boxster 2.5 > 2.7 hill climber

71 914/6 3.0 - gone

'You see Paul, hill climbing is like making love to a beautiful woman. You get your motor running, check your fluids, hang on tight and WHOA..30 seconds later it's all over!' Swiss Tony
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