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NIBrown
Nürburgring


Joined: 10 Oct 2010
Posts: 394
Location: South Wales


PostPosted: Wed Oct 17, 2018 9:56 am    Post subject: Chassis Rails & Bumper Supports Reply with quote

Well, I decided that it was well overdue for checking the condition of the chassis rails and replacement of the bumper supports that I knew were rotten.

Unfortunately I am putting the car up for sale soon as I need the money for a building project, and I wanted to be sure that the new owner had piece of mind on this issue.

More photos to follow on next post, seems there may be a limit on the number per post?

Photos may be in reverse order also!!
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IMG_0953.jpg
 Description:
Rust hole replaced with some nice new steel welded in
 Filesize:  147.48 KB
 Viewed:  578 Time(s)

IMG_0953.jpg



IMG_0947.jpg
 Description:
Off side chassis rail after cleaning down and cutting out a small area of rust....could have been worse, just got it in time!
 Filesize:  246.71 KB
 Viewed:  578 Time(s)

IMG_0947.jpg



IMG_0946.jpg
 Description:
Surface rust to brackets that cleaned up quite easily
 Filesize:  293.8 KB
 Viewed:  578 Time(s)

IMG_0946.jpg



IMG_0945.jpg
 Description:
Off side bracket
 Filesize:  321.68 KB
 Viewed:  578 Time(s)

IMG_0945.jpg



IMG_0944.jpg
 Description:
Off side chassis rail after removing bracket
 Filesize:  277.59 KB
 Viewed:  578 Time(s)

IMG_0944.jpg



IMG_0939.jpg
 Description:
Near side chassis rail cleaned up, phew, no significant rust:-)
 Filesize:  339.14 KB
 Viewed:  578 Time(s)

IMG_0939.jpg



IMG_0936.jpg
 Description:
Inside of near side cavity, looks pretty clean
 Filesize:  285.49 KB
 Viewed:  578 Time(s)

IMG_0936.jpg



IMG_0933.jpg
 Description:
Near side bracket removed and the rust exposed
 Filesize:  334.42 KB
 Viewed:  578 Time(s)

IMG_0933.jpg



IMG_0925.jpg
 Description:
My essential parts from Porsche Cardiff, together with the all important 90% zinc primer and protection wax. Seems that these products are the best available and what everyone else seems to be using.
 Filesize:  357.78 KB
 Viewed:  578 Time(s)

IMG_0925.jpg



IMG_0931.jpg
 Description:
First rusty item to replace
 Filesize:  264.32 KB
 Viewed:  578 Time(s)

IMG_0931.jpg


  
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NIBrown
Nürburgring


Joined: 10 Oct 2010
Posts: 394
Location: South Wales


PostPosted: Wed Oct 17, 2018 10:04 am    Post subject: MORE PHOTOS Reply with quote

More of the progress
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IMG_0974.jpg
 Description:
Near side chassis rail covered in protection wax prior to re-assembly
 Filesize:  94.31 KB
 Viewed:  561 Time(s)

IMG_0974.jpg



IMG_0975.jpg
 Description:
Plate covered in protection wax prior to re-assembly
 Filesize:  123.27 KB
 Viewed:  561 Time(s)

IMG_0975.jpg



IMG_0972.jpg
 Description:
Plate covered in protection wax prior to re-assembly
 Filesize:  168.52 KB
 Viewed:  561 Time(s)

IMG_0972.jpg



IMG_0970.jpg
 Description:
Off side plate cleaned, primed and painted
 Filesize:  148.58 KB
 Viewed:  561 Time(s)

IMG_0970.jpg



IMG_0969.jpg
 Description:
Near side plate, cleaned primed and painted
 Filesize:  170.72 KB
 Viewed:  561 Time(s)

IMG_0969.jpg



IMG_0961.jpg
 Description:
Off side rear of chassis leg primed and painted after removing a very small amount of surface rust
 Filesize:  177.01 KB
 Viewed:  561 Time(s)

IMG_0961.jpg



IMG_0965.jpg
 Description:
Near side rear of chassis leg primed and painted after removing a very small amount of surface rust
 Filesize:  169.45 KB
 Viewed:  561 Time(s)

IMG_0965.jpg



IMG_0963.jpg
 Description:
Off side chassis leg primed and painted
 Filesize:  171.05 KB
 Viewed:  561 Time(s)

IMG_0963.jpg



IMG_0964.jpg
 Description:
Near side chassis leg primed and painted
 Filesize:  216.78 KB
 Viewed:  561 Time(s)

IMG_0964.jpg



IMG_0957.jpg
 Description:
Inside off side chassis rail, again looks pretty clean
 Filesize:  116.28 KB
 Viewed:  561 Time(s)

IMG_0957.jpg


  
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NIBrown
Nürburgring


Joined: 10 Oct 2010
Posts: 394
Location: South Wales


PostPosted: Wed Oct 17, 2018 10:09 am    Post subject: Final photos Reply with quote

The last of the assembly photos, just the bumper, reflector etc to reinstall and I'm there Smile

After plates and supports were re-fitted, I gave everything another good blasting of wax for protection....shouldn't need to get back in there for a very long time!
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IMG_0981.jpg
 Description:
Off side bumper supports fitted, also coated with protection wax
 Filesize:  173.32 KB
 Viewed:  550 Time(s)

IMG_0981.jpg



IMG_0980.jpg
 Description:
Near side bumper supports fitted, also coated with protection wax
 Filesize:  170.5 KB
 Viewed:  550 Time(s)

IMG_0980.jpg



IMG_0977.jpg
 Description:
Off side chassis cavity blasted with a good helping of wax
 Filesize:  183.64 KB
 Viewed:  550 Time(s)

IMG_0977.jpg



IMG_0978.jpg
 Description:
Near side chassis cavity blasted with a good helping of wax
 Filesize:  150.07 KB
 Viewed:  550 Time(s)

IMG_0978.jpg



IMG_0973.jpg
 Description:
Off side chassis rail covered in protection wax prior to re-assembly
 Filesize:  102.59 KB
 Viewed:  550 Time(s)

IMG_0973.jpg


  
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wilsonny
Silverstone


Joined: 01 Dec 2012
Posts: 149
Location: Montreal


PostPosted: Wed Oct 17, 2018 11:55 am    Post subject: Reply with quote

looking good. just be ready for all the smoke after first start up when that wax hits the hot exhaust ! I had people running from the petrol station as smoke rose from the car the first time after I did mine.
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Gazc2
Albert Park


Joined: 08 Nov 2003
Posts: 1705
Location: Scotland


PostPosted: Wed Oct 17, 2018 12:35 pm    Post subject: Reply with quote

Good job, they didnt look too bad compared to some looked pretty much surface rust Thumb
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1990 964 C2
1989 3.2 targa
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NIBrown
Nürburgring


Joined: 10 Oct 2010
Posts: 394
Location: South Wales


PostPosted: Wed Oct 17, 2018 1:05 pm    Post subject: Reply with quote

I was quite pleased with the condition of the chassis, seen some far worse too, but then again, the car has only done 64K!
And to think, this rust must have started to form in the first 14 years, I have never driven it out on a rainy day, let alone on salty roads!!

Thank you for warning me about the smoke, hope it doesn't take too long to burn off Laughing
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badlands
Montreal


Joined: 05 Feb 2015
Posts: 501
Location: London


PostPosted: Wed Oct 17, 2018 1:43 pm    Post subject: Reply with quote

Nice work. They didn't look bad at all, but you never know till you look! Need to get this job done on mine at some point too.
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NIBrown
Nürburgring


Joined: 10 Oct 2010
Posts: 394
Location: South Wales


PostPosted: Wed Oct 17, 2018 2:03 pm    Post subject: Reply with quote

badlands wrote:
Nice work. They didn't look bad at all, but you never know till you look! Need to get this job done on mine at some point too.


I put it off for a long time, as I have seen what a can of worms you can open!

The taking apart is pretty time consuming, as there are many nuts and screws that have to be cut/ground off due to being rusted on!

I found that a dremel with a metal cutting bit that looks a bit like a drill bit was a life saver, it allowed me to cut various seized nuts off without snapping the welded in studs Thumb
I sprayed penetrating oil on all the nuts etc a few days before I started, it helped to get a few of them off.

Now is the time to get stuck in, whilst in winter hibernation....good luck Thumb
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decgraham
Suzuka


Joined: 17 Sep 2008
Posts: 1223
Location: Spain


PostPosted: Wed Oct 17, 2018 4:13 pm    Post subject: Reply with quote

Hi NIBrown,

Good work Thumb

While you've got all the rear end off you might want to check cam chain cover gaskets, cam chain tensioner gaskets, oil bridges as well as top and bottom cam shaft cover gaskets. I didn't and then had to go back in again.

ATB Smile
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Jet Jock
Montreal


Joined: 18 Jul 2005
Posts: 502
Location: Dublin


PostPosted: Wed Oct 17, 2018 7:27 pm    Post subject: Reply with quote

Nice one NIBrown. I tackled this particular issue 2 years ago. I was able to salvage most of the chassis rails etc and went about aqua blasting them and rust proofed before installing again. Goodwork!

Baz
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911UK
Porsche Community
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1997 Porsche 993 Carrera 2

PostPosted: Wed Oct 17, 2018 7:33 pm    Post subject: Reply with quote

nicely done NIBrown Thumb Thumb Thumb
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mashby
Newbie


Joined: 12 Nov 2016
Posts: 42
Location: Coventry


PostPosted: Wed Oct 17, 2018 8:29 pm    Post subject: Reply with quote

Excellent work. You were very lucky.
I'm in the process of doing mine as we speak. Unfortunately they are in a much worse state but the car has done nearly 160k. The wing support brackets were unsalvageable so I have new ones ready to fit and I've had a repair panel made for the near side chassis leg. The off side only needed a 2" square cutting out.
Apart from this rot everything else looked in good shape under there
thumbsup
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NIBrown
Nürburgring


Joined: 10 Oct 2010
Posts: 394
Location: South Wales


PostPosted: Thu Oct 18, 2018 7:37 am    Post subject: Reply with quote

Jet Jock wrote:
Nice one NIBrown. I tackled this particular issue 2 years ago. I was able to salvage most of the chassis rails etc and went about aqua blasting them and rust proofed before installing again. Goodwork!

Baz


Cheers Baz,
I think that every 993 should be looked at irrespective of mileage, I would bet that there is the start of rot in even the lowest mile cars.
A very rewarding job done Thumb
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NIBrown
Nürburgring


Joined: 10 Oct 2010
Posts: 394
Location: South Wales


PostPosted: Thu Oct 18, 2018 7:40 am    Post subject: Reply with quote

mashby wrote:
Excellent work. You were very lucky.
I'm in the process of doing mine as we speak. Unfortunately they are in a much worse state but the car has done nearly 160k. The wing support brackets were unsalvageable so I have new ones ready to fit and I've had a repair panel made for the near side chassis leg. The off side only needed a 2" square cutting out.
Apart from this rot everything else looked in good shape under there
thumbsup


Hi Mashby, sounds like I got away very lightly, good luck with yours, it'll be like new once repaired Thumb
Don't forget to post your work Smile
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NIBrown
Nürburgring


Joined: 10 Oct 2010
Posts: 394
Location: South Wales


PostPosted: Thu Oct 18, 2018 7:43 am    Post subject: Reply with quote

decgraham wrote:
Hi NIBrown,

Good work Thumb

While you've got all the rear end off you might want to check cam chain cover gaskets, cam chain tensioner gaskets, oil bridges as well as top and bottom cam shaft cover gaskets. I didn't and then had to go back in again.

ATB Smile


Hi decgraham,
All looked pretty good down there, so I am hopeful that with the low mileage, they will last for a bit longer Thumb
_________________
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MK7.5 Golf GTD (digi dash)
Skoda Yeti 140TDi 4x4 with 152K Smile
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Cameltoe & Heel
Suzuka


Joined: 26 Jan 2009
Posts: 1135
Location: Preston - Lancs


PostPosted: Thu Oct 18, 2018 7:46 am    Post subject: Reply with quote

This is great work NIBrown.

The chassis leg corrosion issue is a strange one, some suffer much more than others for sure, I'm not sure it's mileage related either.

It's an easy enough fix to do at home if confident enough, think it was Baz that first brought it to our attention.

Good thing with this job is you can sort all the rear end bumper attachment issues at the same time.

I'm currently replacing two rear brake lines that attach to the flexi hose, mine were corroded but boy do they take some shifting. Also replaced part of engine bay skirt/seal which was slightly split and the engine sound pad has been renewed.

How much did the new bumper brackets cost, the three that sit along the top?, was thinking of getting new myself or have them zinc coated.

Trev
 
  
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NIBrown
Nürburgring


Joined: 10 Oct 2010
Posts: 394
Location: South Wales


PostPosted: Thu Oct 18, 2018 12:01 pm    Post subject: Reply with quote

Cameltoe & Heel wrote:
This is great work NIBrown.

The chassis leg corrosion issue is a strange one, some suffer much more than others for sure, I'm not sure it's mileage related either.

It's an easy enough fix to do at home if confident enough, think it was Baz that first brought it to our attention.

Good thing with this job is you can sort all the rear end bumper attachment issues at the same time.

I'm currently replacing two rear brake lines that attach to the flexi hose, mine were corroded but boy do they take some shifting. Also replaced part of engine bay skirt/seal which was slightly split and the engine sound pad has been renewed.

How much did the new bumper brackets cost, the three that sit along the top?, was thinking of getting new myself or have them zinc coated.

Trev


Hi Trev,

You are right, the chassis corrosion issue doesn't really appear to relate significantly to the mileage, weird Question
Not an entirely difficult job to undertake yourself, agreed, but a bit of time and patience is required to remove the seized nuts and bolts frustrated

If you mean the brackets that are pop-riveted onto the plastic bumper, I only had to replace one, as the other were perfect, it was the middle one at £36.59 incl VAT after discount. They come anodised anyway, so no need to zinc plate.
The other bumper support brackets painted black, are 2 per side. Can't remember how much the rear ones were, as I bought these quite some time ago, but the front ones are £78.47 each. These are more likely to corrode over time - mine lasted over 20 years and 64K miles, so in reality, new ones should last longer as these cars are getting used less and less Dont know

I've been into mine replacing brake lines, as I renewed the hoses to all calipers for Goodridge braided and they were seized on, so had to cut the brake pipes! good excuse to bleed the whole system through and refill with some nice DOT 4!
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