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James M-S
Österreich


Joined: 11 Apr 2017
Posts: 908
Location: Derbyshire

2009 Porsche 997 Carrera 2

PostPosted: Tue Sep 04, 2018 10:39 pm    Post subject: Reply with quote

Looks very clean. The clear lamps help.

Am intrigued to drive a boxster/cayman to feel the difference in centre of mass affecting drive through the corners.

Nice Carlton pic too Thumb
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Manual 997.2 c2 :Basalt + gtechniq : H&S + Gundo
 
  
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HSC911
Long Beach


Joined: 23 Jul 2014
Posts: 6351
Location: Bedford


PostPosted: Wed Sep 05, 2018 4:31 am    Post subject: Reply with quote

½cwt wrote:
Am I boring you yet?....


Not at all! Grin

Were you based at Bedford when you worked at Palmer's Dont know

We need to do a local meet up, if you're into Fords then the Northants Ford RS owners club are having their annual show this Sunday, maybe worth a peek Thumb
 
  
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½cwt
Trainee


Joined: 01 Sep 2018
Posts: 52
Location: Kettering, UK


PostPosted: Wed Sep 05, 2018 4:51 am    Post subject: Reply with quote

I was stores manager at Bedford from 2004 to 2007 supporting both the corporate fleet and Formula Palmer Audi race team fleet. Main task was to update from paper based system logged in the database one a week to a live stock and re-order system. I was only taken on for 'about a year' originally to do the systems changes but I was enjoying it and the didn't ask me to go after 12 months so I stayed until they remembered it was just and interim job for the development and implementation of the new system.

I'm not a great fast Ford fan but do have some attraction. The more anonymous early cars I referred to included a Mk2 Fiesta 1400S and a Mk3 1600S but never an RS. As an aside, my first every paid work was a summer job at the Cosworth road engine assembly facility in Wellingborough for 5 weeks in 1985. I just wrote to them and asked saying I was looking into an engineering career, they interviewed me and gave me the job for work experience! Doubt it would happen now.

Also in my time as a rally navigator I've competed in both Sapphire and Escort RS Cosworths. The owner of the Escort even let me drive it on the test stage before one event. Awsome! Very Happy

Last edited by ½cwt on Wed Sep 05, 2018 5:00 am; edited 1 time in total
 
  
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½cwt
Trainee


Joined: 01 Sep 2018
Posts: 52
Location: Kettering, UK


PostPosted: Wed Sep 05, 2018 4:53 am    Post subject: Reply with quote

Clear lights was one of the factors that drew me to this one, also happened to be closet to home, and they sit particularly well with the silver IMHO.
 
  
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HSC911
Long Beach


Joined: 23 Jul 2014
Posts: 6351
Location: Bedford


PostPosted: Wed Sep 05, 2018 5:00 am    Post subject: Reply with quote

½cwt wrote:
Also in my time as a rally navigator I've competed in both Sapphire and Escort RS Cosworths. The owner of the Escort even let me drive it on the test stage before one event. Awsome! Very Happy


We may have crossed paths before then Very Happy

I'm in Ravensden, we used to run the shop. Uncle still runs the garage thumbsup

You may recognise the area, but here is my other car which I just pushed out of the garage after 4ish years to give her a clean Grin









Thumb
 
  
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½cwt
Trainee


Joined: 01 Sep 2018
Posts: 52
Location: Kettering, UK


PostPosted: Mon Oct 01, 2018 6:03 pm    Post subject: Reply with quote

Had the Boxster S for a month now and have ordered various parts from Design 911 to fix some of the niggles. AC not working confirmed as a rotted our left had condenser and I also got a whole dust pan full of crud out of both left and right cooling ducts and rads. Obviously not been done in a while. Ordered the whole set of 2 condensers, drier and seals as a kit(on off at Design911) so it is all new once fitted, and I'll hopefully have one spare old condenser in case of future issues if it doesn't leak. Are there any after market wire grilles out there to help stop straw, grass and twigs etc?

Whilst investigating the u/s reversing lights I found that all 4 CV boot were split or perished. Started on these this weekend and have found, unlike the advice on line, that on the driver's side (RHD car) at least you can get the CV joint off the inner end without undoing any suspension ball joints or dropping the exhaust manifold; just jack up the upright to compress the suspension and the inboard end of the shaft will drop enough for the CV joint to clear the drive flange and transmission case so you can drift it off with the shaft in situ. I'll find out about the other side next weekend... but apparently it is less spacious from the bit of info I've gathered.


Back to the reversing light switch, this is on the tail of the gearbox near the top on the right hand side. No online images show this position. Still a relatively easy fix as I was able to get a 19m deep socket on a wobble extension over the switch assembly and the whole ratchet handle in there without taking anything off except the wheel. The electrical connector is a bit fiddly however. First job sorted. Thumb

The cover for the clear wind deflector panel didn't come with the car so my wife has made me one up in brushed black cotton with a draw string and even added a Porsche sew on badge to the bag. This will protect it nicely in the slot in the rear stowage on the rear shelf.
 
  
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James M-S
Österreich


Joined: 11 Apr 2017
Posts: 908
Location: Derbyshire

2009 Porsche 997 Carrera 2

PostPosted: Mon Oct 01, 2018 8:38 pm    Post subject: Reply with quote

To protect the new condensers from leaves/twigs/fag butts, options are:

Zunsport (overpriced), speak to DW performance in Wellingborough for their similar (but better looking) solution, or DIY with some black mesh while the bumper is off.

have a look in the boyracer section of Halfords, as they might have mesh grills to use as donors.

https://www.halfords.com/motoring/car-accessories/exterior-styling/simply-black-aluminium-mesh-1m-x-0-25m

Secure with drilled holes and cable ties.
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Manual 997.2 c2 :Basalt + gtechniq : H&S + Gundo
 
  
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½cwt
Trainee


Joined: 01 Sep 2018
Posts: 52
Location: Kettering, UK


PostPosted: Mon Oct 01, 2018 9:22 pm    Post subject: Reply with quote

Thanks for info on the grille/protection. I dropped into DW not long ago just to say 'Hi' as they are my nearest independent, only about 8 miles away, so I'll see what they have first.
 
  
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½cwt
Trainee


Joined: 01 Sep 2018
Posts: 52
Location: Kettering, UK


PostPosted: Sat Oct 06, 2018 7:50 am    Post subject: Reply with quote

OK, this is either 'Legend' or 'lunatic'. CV boot replacement.

Not being one for believeing everything ont eh internet I set about changing the 4 CV boots on the Boxter S. Right hand side went pretty well albeit slow as it was the first time tackling this on this type of car. Only real issue was that the inboard CV was quite tight ont eh shaft and needed a lot of persuasion to slide off. Unlike the write ups it IS possible to do this without dropping the manifold or disconnecting any of the suspension except the anti-roll bar. There is enough space to remove the CV joint by playing with a jack under the hub raising and lowering it to get different angles of tilt. Only problem I had was I put the centre back onto the shaft with the undercut splines at the gearbox inner end so had knocked it on pretty hard whist trying to get the circlip on. This took a LOT of persuasion to come off using the flat end of a broken screwdriver shaft which just happened to have a slight curve in it also to make it easier …(!) as the drifter. Right side all done.

Full of confidence and possibly a bit of arrogance I started teh left side. Now the gearbox has the diff crown wheel this side so the shaft is shorter antherefore there is a bit less space. All was going well until I really could not get the whole CV off. The inner cover that the boot fits to was too stuck in place to be able to get it off and so I couldn't get the tilt on the CV to get it out but I could get the centre, the race and the ball bearing out taking it apart on the shaft. I did dissconncet the track control arm and the training link to get a bit of movement for the hub but still not enough clearance. Here's the madness bit. What if a CV boot would go through the centre of the CV outer? Well, the GKN CV boot kits I got with a bit of persuaion did just that! I can't beleive I got away with this. So cutting the old boots off with snips, the new boots could be fitted with the clips having to be opened up to go over the shaft rather than slid on. Using lots of brake cleaner I cleand up everything around the CV to minimise any grit transfer and with difficulty rebuilt the CV onto the shaft in situ.

All this was done with axle stands only on the drive, no ramp.

Job 2 done Thumb

3 notes - I don't have anything that could have cracked off the hub nut and 2 the exhaust manifold bolts are VERY corroded so didn't want to risk undoing these and round off or breaking one. I also dont have a joint splitter that would separate the bottom hub ball joint.

One thing; please don't ask me how long it took. 10 hours in a garage might be worth it unles you are up for a real challenge. I probably wont' do it this way again!

Next job AC condensers; hopefully a little more staight forward.
 
  
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½cwt
Trainee


Joined: 01 Sep 2018
Posts: 52
Location: Kettering, UK


PostPosted: Mon Oct 22, 2018 10:12 pm    Post subject: Reply with quote

Got the new air con condensers and the drier fitted with no issues at all. Drier was a bit fiddly to get out of clamp so removed whole clamp. Just need a re-gas now.

Also have spotted some coolant leaking which I've posted another thread about but whilst trying to track it down I found the centre under tray is damaged and only 4 clips were fitted, 2 of which were pretty rotten. Also the 2 diagonal arms under the fuel tank were very corroded so brushed them off and gave them a coat of black paint. Did find a dent in the bottom of the luggage compartment well near where these two supports bolt in place so touched in the exposed metal as well. Put this a long way down ont eh nice to fix some time list.

Hopefully the only job to get through next MOT in a few months is 2 new headlamp washer assemblies.

Other tasks I've decided on it so swap out the CD holder in the lower centre console for an empty tray. You need somewhere to put a mobile phone these days; the other is to fit a new head unit with DAB and Bluetooth for music streaming but nothing flash. Both relatively cheap jobs whilst saving pennies for things like washer jets and cruise control.
 
  
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The return of Marty Wild
Barcelona


Joined: 04 Nov 2016
Posts: 1363



PostPosted: Tue Oct 23, 2018 12:28 pm    Post subject: Reply with quote

I had a pair of the Zunsport on my Cayman, wasn’t massively impressed so sold them on here.

Got some guards/LED DRLs from an American chap in the end. But not sure they fit a Boxster, don’t think they do.
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Life's too short for cr4ppy cars, keep it German!

Cayman S 987.1
 
  
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½cwt
Trainee


Joined: 01 Sep 2018
Posts: 52
Location: Kettering, UK


PostPosted: Wed Oct 24, 2018 5:36 pm    Post subject: Reply with quote

I dropped into DW in Wellingborough and they happen to have a 997 they'd just fitted grilles to. They looked good enough for me to plan to part with my money. When I do I'll post some pics but don't hold your breath, a lot of nice to haves that I'm planning for the car but I need to prioritise.
 
  
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½cwt
Trainee


Joined: 01 Sep 2018
Posts: 52
Location: Kettering, UK


PostPosted: Sat Nov 10, 2018 10:41 pm    Post subject: Reply with quote

Took a bit of a break from doing work on the car as the weather has got colder and wetter, however I finally got the re-gas of the AC done today and all good so it was just rotten condensers.

Also fitted a new head unit (details in a another thread) and have swapped the CD storage unit in the lower console for a bin (thanks 9apart). Now have space for wallet and phones as well as oddments.

I've also bought a half cover for the winter to give some protection from the worst of the weather.

I have noticed in the colder weather that it takes time for the gearbox to warm up as it is rather baulky when the oil is still warming through. All fine once up to temp.

Still trying to trace the minor coolant leak. It only seem to lose fluid when up to temp and under pressure so it is manageable for now. Going to get it on a ramp sometime to check it more easily than just working off the floor.
 
  
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½cwt
Trainee


Joined: 01 Sep 2018
Posts: 52
Location: Kettering, UK


PostPosted: Sun Apr 07, 2019 11:49 am    Post subject: Reply with quote

After another break in work on the car I've picked up a few small jobs in preparation for its MOT next month. It has also been to my local indy (DW Performance) for a service and 'box oil change. Much crisper throttle response on new plugs and smoother 'box on fresh oil. Pleased that the old fluids were just old and not showing any other issues. The only advisory other than finally establishing the location of a minor water leak is that the coffin arm rubbers are showing their age and could do with replacement in the next 12 months or so.

I've bought and fitted the new headlamp washers and now only was the lamps and not most of the road around the car and it also keeps the washer fluid in the tank when I fill it up.

I've replaced the ash tray in the console with the storage tray option (Having an alarm problem following this, the cause of which is proving a mystery but its not the locking storage cover microswitch) and replaced the damaged aero lips on the leading edge of the wheel arches as one was missing completely and two were damaged.

Planning the first major expedition with a trip to France in late May. Must get cruise control retro fitted before that...
 
  
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ragpicker
Estoril


Joined: 14 Apr 2013
Posts: 3949
Location: North East England


PostPosted: Sun Apr 07, 2019 2:33 pm    Post subject: Reply with quote

Sounds like you've been enjoying your boxster 1/2cwt!

Cracking thread but its just missing a few more interesting pics of the car whilst you're working on it - I'd love to see the CV change on the axle stands as it was hard enough on my lift.. The inboard drivers rear being the biggest PITA.

Are you going to install the cruise yourself?
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996 turbo - Available to buy if you're interested: http://911uk.com/viewtopic.php?t=131025&highlight=
986 S - usually in pieces: http://911uk.com/viewtopic.php?t=112626
955 Cayenne Turbo - a work in progress: http://911uk.com/viewtopic.php?t=131286&highlight=
 
  
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½cwt
Trainee


Joined: 01 Sep 2018
Posts: 52
Location: Kettering, UK


PostPosted: Sun Apr 07, 2019 9:31 pm    Post subject: Reply with quote

Ah, CV boots.

Near side was a definite PITA!. Managed to take the inner CV race apart on the shaft and got the inner off but couldn't manoeuvre teh various bits to the right postions to get the outer off the shaft by about 2mm. In the end a moment of madness led to the idea of pulling the boots through the joint, and with a bit of lubrication that is how the nearside CV boots got into their correct postions. Rebuilding a CV joint onto a shaft under the car outside in fading light without getting the outer off was a real joy! But not joyful enough to stop to take pics I'm afraid. Took about 10 hours to do both sides and I learned a lot.

Tempted to do cruise but I'm not too keen on electrics. Might talk to my Indy to see if he's OK for me to source the parts and do the mechanical bits and run the cables with him just doing final connections and activation.

I've also got to track down another electrical fault with the interior lighting as I mentioned.

Still loving driving the car, really sweet today with new plugs sharpening up the throttle response and some fun in the damp this afternoon. thumbsup
 
  
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½cwt
Trainee


Joined: 01 Sep 2018
Posts: 52
Location: Kettering, UK


PostPosted: Fri Apr 12, 2019 9:34 pm    Post subject: Reply with quote

Come to an arrangement with my indy. I'll do the column switch change and run the cables for the cruise system, he'll then connect up and code it in. Got a 4 stalk column switch on line second hand from a breaker today so hopefully cruise control for less that £400. @ragpicker I will take pictures of this process.

Also had a chance to drive it a little more since the service. plug change has really improved the throttle response and power too it feels. After years in diesels I'd forgotten just how much a set of new spark plugs can pep up a motor, particularly a normally aspirated one.
 
  
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½cwt
Trainee


Joined: 01 Sep 2018
Posts: 52
Location: Kettering, UK


PostPosted: Sat Apr 13, 2019 11:24 am    Post subject: Reply with quote

Got round to taking pictures of the centre consoles with all the storage options updated, no CD storage or ash tray units and new head unit for audio system. New front speakers planed shortly and possibly speakers to the rear parcel shelf unit, no door speakers fitted in this one.
 



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