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997_2_C4S
Newbie


Joined: 27 Nov 2019
Posts: 15



PostPosted: Tue Dec 03, 2019 1:30 pm    Post subject: 997.2 Underbody Refurb and Corrosion Reply with quote

So... I bought a 'mint' and cherished 49000 mile 997.2 C4S from a renowned dealer, and they were great and the car has great provenance. i went into this with my eyes open knowing this was a 10 year old UK car, and asked on various forums about rustproofing. Without exception, every single person told me that Porsche's factory rustproofing would be fine and I wouldn't need to do anything - just use it, rain or shine, winter or summer. I know this wouldn't be the case so the first thing I have done is book it in to a specialist and have all the plastic under trays, sill covers, arch liners and heat shields removed so they can inspect it.

Inevitably they found rust. Everywhere.

Of course, I expected the power coating to have failed after 10 years which of course it had, but I didn't expect the sills to have started to go along the seams.

So, pretty much everything that was concealed is now being cleaned, blasted, treated, painted and then Dinitrol treated, in order to give me peace of mind. I suspect that if I hadn't done this, I would be failing MOTs in a few years.

Pretty much sure everyone will tell me that mine is the exception, but there isn't a single reason to thing it is. Always garaged, used as 2nd car, cherished at main dealer or specialist, etc etc.

As all cars, these are fragile and need proper maintenance - not just the visible bits.
 



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Rojdog
Silverstone


Joined: 08 Nov 2018
Posts: 123
Location: Essex


PostPosted: Tue Dec 03, 2019 3:29 pm    Post subject: Reply with quote

That looks pretty bad to be fair.

I bought a 997.2cs about a year ago with a fair few miles more than yours. I have a lift at home so stripped and inspected all the underside of the car and found hardly any rust/corrosion.

There was a pipe clamp and 2 diagonal braces that connect to the front sub frame (cheap to replace.) The exhaust clamps and fixtures are well rusted but that will happen no matter what.

Looks likely that your car may have lived by the seaside for a large part of its life?

Good you caught it now and not later as you said.
 
  
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Phil 997
Le Mans
Le Mans


Joined: 05 Dec 2015
Posts: 15551
Location: Bournemouth,Dorset

2009 Porsche 997 Carrera 4S

PostPosted: Tue Dec 03, 2019 3:36 pm    Post subject: Reply with quote

Interesting post, I have had the covers off a few times and it didnt look quite as bad as that ,although it has needed a new tandem pump, HP fuel pump, all coolant lines . just out of interest whats the cost to have everything cleaned up painted and resealed . the reason I ask is that I live on the south coast and it may be prudent at some point to reprotect the underside in a more full way than the regular ACF50 treatment. Thumb
_________________
911 Owners,Some Invest In The Future,
Others Enjoy The Moment Today.
 
  
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997_2_C4S
Newbie


Joined: 27 Nov 2019
Posts: 15



PostPosted: Tue Dec 03, 2019 4:03 pm    Post subject: Reply with quote

Phil 997 wrote:
Interesting post, I have had the covers off a few times and it didnt look quite as bad as that ,although it has needed a new tandem pump, HP fuel pump, all coolant lines . just out of interest whats the cost to have everything cleaned up painted and resealed . the reason I ask is that I live on the south coast and it may be prudent at some point to reprotect the underside in a more full way than the regular ACF50 treatment. Thumb


About £2k. Seems money well spent
 
  
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Phil 997
Le Mans
Le Mans


Joined: 05 Dec 2015
Posts: 15551
Location: Bournemouth,Dorset

2009 Porsche 997 Carrera 4S

PostPosted: Tue Dec 03, 2019 4:11 pm    Post subject: Reply with quote

997_2_C4S wrote:
Phil 997 wrote:
Interesting post, I have had the covers off a few times and it didnt look quite as bad as that ,although it has needed a new tandem pump, HP fuel pump, all coolant lines . just out of interest whats the cost to have everything cleaned up painted and resealed . the reason I ask is that I live on the south coast and it may be prudent at some point to reprotect the underside in a more full way than the regular ACF50 treatment. Thumb


About £2k. Seems money well spent


I would agree 2k to give it another 10 years life Thumb Thumb
_________________
911 Owners,Some Invest In The Future,
Others Enjoy The Moment Today.
 
  
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Rojdog
Silverstone


Joined: 08 Nov 2018
Posts: 123
Location: Essex


PostPosted: Tue Dec 03, 2019 4:34 pm    Post subject: Reply with quote

Phil 997 wrote:
997_2_C4S wrote:
Phil 997 wrote:
Interesting post, I have had the covers off a few times and it didnt look quite as bad as that ,although it has needed a new tandem pump, HP fuel pump, all coolant lines . just out of interest whats the cost to have everything cleaned up painted and resealed . the reason I ask is that I live on the south coast and it may be prudent at some point to reprotect the underside in a more full way than the regular ACF50 treatment. Thumb


About £2k. Seems money well spent


I would agree 2k to give it another 10 years life Thumb Thumb


Would have thought substantially less if not in bad shape just to wash and under seal?
 
  
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997_2_C4S
Newbie


Joined: 27 Nov 2019
Posts: 15



PostPosted: Tue Dec 03, 2019 4:58 pm    Post subject: Reply with quote

Rojdog wrote:
Phil 997 wrote:
997_2_C4S wrote:
Phil 997 wrote:
Interesting post, I have had the covers off a few times and it didnt look quite as bad as that ,although it has needed a new tandem pump, HP fuel pump, all coolant lines . just out of interest whats the cost to have everything cleaned up painted and resealed . the reason I ask is that I live on the south coast and it may be prudent at some point to reprotect the underside in a more full way than the regular ACF50 treatment. Thumb


About £2k. Seems money well spent


I would agree 2k to give it another 10 years life Thumb Thumb


Would have thought substantially less if not in bad shape just to wash and under seal?


Ummm - you can't wash rust off, or steel when its swollen. It needs shot blasting, treating, painting, then protecting, and most of the elements removed if it's to be done properly. It's 8 days work. I had a new Defender done by the same people and it was £1100 with no preparation needed, and that took a week to do properly. So 2K including remedial work seems fair.
 
  
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Rojdog
Silverstone


Joined: 08 Nov 2018
Posts: 123
Location: Essex


PostPosted: Tue Dec 03, 2019 5:34 pm    Post subject: Reply with quote

997_2_C4S wrote:
Rojdog wrote:
Phil 997 wrote:
997_2_C4S wrote:
Phil 997 wrote:
Interesting post, I have had the covers off a few times and it didnt look quite as bad as that ,although it has needed a new tandem pump, HP fuel pump, all coolant lines . just out of interest whats the cost to have everything cleaned up painted and resealed . the reason I ask is that I live on the south coast and it may be prudent at some point to reprotect the underside in a more full way than the regular ACF50 treatment. Thumb


About £2k. Seems money well spent


I would agree 2k to give it another 10 years life Thumb Thumb


Would have thought substantially less if not in bad shape just to wash and under seal?


Ummm - you can't wash rust off, or steel when its swollen. It needs shot blasting, treating, painting, then protecting, and most of the elements removed if it's to be done properly. It's 8 days work. I had a new Defender done by the same people and it was £1100 with no preparation needed, and that took a week to do properly. So 2K including remedial work seems fair.


Umm..... 'if not in bad shape' as in not already rusted.
 
  
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GMG
Nürburgring


Joined: 07 Jan 2018
Posts: 459
Location: Devon


PostPosted: Tue Dec 03, 2019 5:35 pm    Post subject: Reply with quote

...blimey...my 2003 , 70k miles 996 is virtually rust free in comparison?

Your car must have either lived by the sea or perhaps was parked on grass for long periods?

Those sill seams are in a terrible state...make sure they remove the ***** shields
to inspect...
 
  
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b8575
Newbie


Joined: 08 Nov 2019
Posts: 13



PostPosted: Tue Dec 03, 2019 7:52 pm    Post subject: Reply with quote

997_2_C4S wrote:
Ummm - you can't wash rust off, or steel when its swollen. It needs shot blasting, treating, painting, then protecting, and most of the elements removed if it's to be done properly. It's 8 days work. I had a new Defender done by the same people and it was £1100 with no preparation needed, and that took a week to do properly. So 2K including remedial work seems fair.


Do you mind me asking where are you getting the work done? I’m thinking of doing something similar myself
 
  
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C4Silver
Spa-Francorchamps


Joined: 14 Aug 2019
Posts: 272



PostPosted: Tue Dec 03, 2019 8:05 pm    Post subject: Reply with quote

I'd agree with the general consensus, that's fairly severe rust and the swolen bar on the last few shots looks like a hand rail at the end of a pier..... The swelling seams looks like it's been submerged.

I've often wonderd about having mine treated, having had 6 Defenders i can sympathise with you on having to have them treated 'Wayoyl" in my case, and NO not done by you know who.......

Only to sell them a few years later so the preventative rust remedy would benefit future owners and not me, I have a car that a magazine wanted to do a photoshoot on Pendine sands........ It's Italian so you can imagine how much anti corrosion is missing from that under belly..... I declined the offer and still have the car, I'd hate to the what the dreaded Tin Worm would have done to it having been ragged around a salt water environment all afternoon......
 
  
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997_2_C4S
Newbie


Joined: 27 Nov 2019
Posts: 15



PostPosted: Tue Dec 03, 2019 8:25 pm    Post subject: Reply with quote

b8575 wrote:
997_2_C4S wrote:
Ummm - you can't wash rust off, or steel when its swollen. It needs shot blasting, treating, painting, then protecting, and most of the elements removed if it's to be done properly. It's 8 days work. I had a new Defender done by the same people and it was £1100 with no preparation needed, and that took a week to do properly. So 2K including remedial work seems fair.


Do you mind me asking where are you getting the work done? I’m thinking of doing something similar myself


Moore's Motor Cars in Clevedon. Totally amazing.
 
  
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Rojdog
Silverstone


Joined: 08 Nov 2018
Posts: 123
Location: Essex


PostPosted: Tue Dec 03, 2019 8:36 pm    Post subject: Reply with quote

I've just realised what your last pic is, just order 2 new ones they are cheap and pressed out of such flimsy sheet rather than having them spend time cleaning up. They had also started to go on mine but just on top.
 
  
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maph
Monza


Joined: 01 Feb 2017
Posts: 188



PostPosted: Tue Dec 03, 2019 9:42 pm    Post subject: Reply with quote

997_2_C4S wrote:


Moore's Motor Cars in Clevedon. Totally amazing.


Good to know, short walk from me 👍🏻
_________________
2012 997.2 Turbo S - ES650
 
  
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b8575
Newbie


Joined: 08 Nov 2019
Posts: 13



PostPosted: Tue Dec 03, 2019 9:43 pm    Post subject: Reply with quote

997_2_C4S wrote:
b8575 wrote:
997_2_C4S wrote:
Ummm - you can't wash rust off, or steel when its swollen. It needs shot blasting, treating, painting, then protecting, and most of the elements removed if it's to be done properly. It's 8 days work. I had a new Defender done by the same people and it was £1100 with no preparation needed, and that took a week to do properly. So 2K including remedial work seems fair.


Do you mind me asking where are you getting the work done? I’m thinking of doing something similar myself


Moore's Motor Cars in Clevedon. Totally amazing.


Thanks! They look good but alas, a little bit far from me
 
  
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997_2_C4S
Newbie


Joined: 27 Nov 2019
Posts: 15



PostPosted: Wed Dec 04, 2019 6:01 am    Post subject: Reply with quote

Great news from the garage:

Don’t worry, I would say if I thought if wasn’t OK!
It probably looks worse than it is. The rusty thing on the left hand side of the photo is a sill tray retaining fastener, all of which are very rusty but there functional strength isn’t impaired. The blistering is just the blanket sprayed seam sealer coating that the water has got behind which is being pushed out.
To rectify this we will locally remove the coating around the failed areas, you will find just outside of this the condition will be perfect. We will then prep the corroded bits, apply a rust converter/epoxy product (Dinitrol RC900) then along with all the other bits will brush apply a specialist black epoxy resin paint, which is an exceptionally good primer in these situations. Once dry we will seal the area with a brush-able seam sealer. Followed by the various Dinitrol waxes.
Also shining a light inside the sill through one of the vent holes and peering down another reveals the internal condition to be excellent. We will of course wax inside these cavities. (Some of these may indirectly vent internally behind the carpet etc so some wax solvent/vapour may be able to be smelt inside the car for a period of time but given the potential vulnerability to corrosion i would recommend treating them)
 
  
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alpinaman
Montreal


Joined: 21 Feb 2012
Posts: 580



PostPosted: Wed Dec 04, 2019 6:52 pm    Post subject: Reply with quote

Thats shocking really..

I didnt realise 997's are having rust issues.

I thought they were galvanised?
 
  
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997_2_C4S
Newbie


Joined: 27 Nov 2019
Posts: 15



PostPosted: Wed Dec 04, 2019 7:35 pm    Post subject: Reply with quote

alpinaman wrote:
Thats shocking really..

I didnt realise 997's are having rust issues.

I thought they were galvanised?


The body is. And there’s no problem on the body except for one seam which is being easily sorted. None of the other metal parts - linkages, rods, bars, arms etc are - they’re all powder coated and inferior grade steel. The sill cover is designed to permanently hold water which is a problem. If anyone hasn’t taken theirs off, they should.
 
  
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sim996
Monza


Joined: 05 Aug 2017
Posts: 204



PostPosted: Wed Dec 04, 2019 8:37 pm    Post subject: Reply with quote

I've not seen many cars where the cross bars aren't rusty, they are easily sorted. Most people reading this will have cars in similar condition if they looked properly.

Get your undertrays off folks. These cars are getting on now and we pride them as the daily supercar, but it comes at a price.

I'm getting mine sorted soon, I've powder coated all the intercooler, gearbox and rad brackets, inner arches painted and had the subframe off. Just need to properly get the old underseal off and recoat.

Thanks for the pics.
 
  
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