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997.2 Underbody Refurb and Corrosion

997_2_C4S

Active member
Joined
27 Nov 2019
Messages
33
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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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.
 
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:
 
Phil 997 said:
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
 
997_2_C4S said:
Phil 997 said:
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:
 
Phil 997 said:
997_2_C4S said:
Phil 997 said:
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?
 
Rojdog said:
Phil 997 said:
997_2_C4S said:
Phil 997 said:
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.
 
997_2_C4S said:
Rojdog said:
Phil 997 said:
997_2_C4S said:
Phil 997 said:
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.
 
...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...
 
997_2_C4S said:
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
 
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......
 
b8575 said:
997_2_C4S said:
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.
 
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.
 
997_2_C4S said:
Moore's Motor Cars in Clevedon. Totally amazing.

Good to know, short walk from me 👍🏻
 
997_2_C4S said:
b8575 said:
997_2_C4S said:
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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