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NedHan79
Hockenheim


Joined: 08 Nov 2018
Posts: 679



PostPosted: Sat Nov 09, 2019 9:04 pm    Post subject: 996.1 aero restoration Reply with quote

For anyone interested in seeing what my sills looked liked when I started to investigate I’ll stick some pictures up. I’ve always wanted to do a thread on my ownership on here but never had the time. I have however, recorded some of the goings on on instagram. For no more reason than it’s just handy to stick on an update with some pictures.

What started out as brake pipes over the gearbox for mot in June, quickly turned into a major job.
The sills were completely rotten, the rear arches not so bad but I thought, when in Rome and all that.
Basically I’ve made everything from scratch. Definitely not opc standard but I’m quite happy with it on the whole. I’d do a lot of things different if I had to start again but you live, you learn.

The story on instagram is my story so far. A LONG way from finished but a new arrival to the family member is due so progress will pretty much stop for a while.

I’m open to any ideas on work I have still to do.

Anyways my instagram is @nedhannon

Have a look and fire away with any questions. I’d say I’ve over 1000 photos of work so far, not all great though as I’m working in a tight space.

I’ll probably not put many photos on here as I seem to have to snapshot them again for some reason for them to upload.

Feel free to browse.lol

Already having trouble with the photos.lol
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NedHan79
Hockenheim


Joined: 08 Nov 2018
Posts: 679



PostPosted: Sat Nov 09, 2019 9:25 pm    Post subject: Reply with quote

Rear jacking point
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NedHan79
Hockenheim


Joined: 08 Nov 2018
Posts: 679



PostPosted: Sat Nov 09, 2019 9:27 pm    Post subject: Reply with quote

At the front
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NedHan79
Hockenheim


Joined: 08 Nov 2018
Posts: 679



PostPosted: Sat Nov 09, 2019 9:29 pm    Post subject: Reply with quote

Inside the front drivers side sill
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NedHan79
Hockenheim


Joined: 08 Nov 2018
Posts: 679



PostPosted: Sat Nov 09, 2019 9:32 pm    Post subject: Reply with quote

Next piece of the sill above the front jacking point
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NedHan79
Hockenheim


Joined: 08 Nov 2018
Posts: 679



PostPosted: Sat Nov 09, 2019 9:34 pm    Post subject: Reply with quote

New arch made and tacked in. No real need for new arches now but I don’t want to do this again
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TV8
Newbie


Joined: 08 Nov 2019
Posts: 43
Location: Bromley


PostPosted: Sat Nov 09, 2019 9:53 pm    Post subject: Reply with quote

A big surprise, I didn't think that these cars rusted! Good work if you fixed that
 
  
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coullstar
Albert Park


Joined: 15 Sep 2015
Posts: 1640
Location: Aberdeen/Torphins


PostPosted: Sat Nov 09, 2019 11:18 pm    Post subject: Reply with quote

TV8 wrote:
A big surprise, I didn't think that these cars rusted! Good work if you fixed that


Oh they do, just starting to come through now on the earlier cars. There only just starting so for many theres still time to protect and prevent this. My rear arches have started to go as well.

Correct me if Im wrong but this is an aerokit car so has the side skirts. Ive got a feeling those skirts are hiding a multitude of sins on a lot of car.

I'll look you up on Instagram and good luck getting it all done.
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NedHan79
Hockenheim


Joined: 08 Nov 2018
Posts: 679



PostPosted: Sat Nov 09, 2019 11:47 pm    Post subject: Reply with quote

Much more of a surprise than I ever expected. Yes on the aero kit. Genuine from new. The skirts hold all the dirt and therefore the water. Same as any car with them. They fold right underneath past the fold in the sill so they collect everything going. I never thought it’d be that bad. The arches in fairness weren’t bad at all. I just got a bit carried away.

Got you back on instagram there coulstar. I had followed your thread on here so I’m familiar with your wheel fettish Floor Floor
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ditchvisitor
Monza


Joined: 09 Oct 2017
Posts: 179
Location: Oxfordshire


PostPosted: Sun Nov 10, 2019 7:25 am    Post subject: Reply with quote

Wow that’s pretty scary what was underneath!! How easy are the sill covers to remove? It’s a job I want to do on my GT3 but haven’t gotten around to it yet.
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"Try to stay in the middle of the air, do not go near the edges of it. The edges of air can be recognised by the appearance of ground, buildings, sea, trees and interstellar space. It is much more difficult to fly there!!"

Current: 996 GT3 MK1
Previous: 89 Carrera 3.2
Previous: 986 Boxster S
 
  
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MisterCorn
Dijon


Joined: 08 Jan 2011
Posts: 7333
Location: Nottingham, England

2004 Porsche 996 Turbo

PostPosted: Sun Nov 10, 2019 8:00 am    Post subject: Reply with quote

The sill covers can be a pain to remove. I have recently taken them off my 190k mile C4 to do the bodywork, but it was nothing like as bad as this.

MC
 
  
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Griffter
Spa-Francorchamps


Joined: 22 May 2016
Posts: 368



PostPosted: Sun Nov 10, 2019 8:36 am    Post subject: Reply with quote

Good work Nedhan.

Makes a bit of a joke of a potential MOT failure for brake pipes!
 
  
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NedHan79
Hockenheim


Joined: 08 Nov 2018
Posts: 679



PostPosted: Sun Nov 10, 2019 11:55 am    Post subject: Reply with quote

Thanks guys. By sill covers do you mean the skirts? Mine may have been off before due to a bodged repair at the back of the sill. Clips at the bottom are easy but there was a serious amount of bonding along the top edge. Not easy but what lay beneath was obviously worse.

I’d image a gt3 could be a lot worse condition as there’s no under seal from the factory but then again, it might not be as the factory sealer holds in the water if it gets broken. A gt3 would have to get new sills in this case due to value. My car has an accident history though I can’t really see where so I don’t have the worry of originality.

The sill themselves can only be bought from porsche. No after market parts available yet as far as I could find. Also they’re in 2 sections. The sill only comes from the front to about the rear of the door and the rear section is part of the quarter panel. I just didn’t have the means to buy these so I had to improvise. A lot of work.
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Pauldeacs80
Newbie


Joined: 30 Jul 2019
Posts: 35



PostPosted: Tue Nov 12, 2019 8:39 pm    Post subject: Reply with quote

Urghhh looks terrible but I’m expecting my 98 to be the same when I remove the aero skirts. The jacking points on mine all look a little rough, in fact I have managed to poke my finger up through one Of the rear ones

Ah well, I guess many 21 year old cars will also have rust of this nature.
 
  
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NedHan79
Hockenheim


Joined: 08 Nov 2018
Posts: 679



PostPosted: Tue Nov 12, 2019 9:23 pm    Post subject: Reply with quote

Pauldeacs at least your on the case. It's not going to be pretty but there's no point denying its there. Just get stuck in. Don't be loosing any sleep,over it.


We're not the first to get here, maybe just the first to admit it
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Pauldeacs80
Newbie


Joined: 30 Jul 2019
Posts: 35



PostPosted: Wed Nov 13, 2019 8:44 pm    Post subject: Reply with quote

What gauge steel did you use for the repairs? Also did you buy new jacking points or just fab something up? I see the jack points s are all available from Porsche but ends up being about £500 for the 4x
 
  
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NedHan79
Hockenheim


Joined: 08 Nov 2018
Posts: 679



PostPosted: Wed Nov 13, 2019 10:10 pm    Post subject: Reply with quote

I can’t remember on the gauge. My local motor factors had a choice. 0.8 and 1.0mm iirc. I went for the thicker of the 2.

On the jacking points, I made them from 2mm. I work in a small engineering shop so I have access to plasmas and a brake press. Made things a lot easier. Measured the old ones, plasma cut and folded. Cost me nothing but 20 mins and a lick of paint. After welding them in, loaded the insides with seam sealer and then plenty of stone chip to keep the water out
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Pauldeacs80
Newbie


Joined: 30 Jul 2019
Posts: 35



PostPosted: Thu Nov 14, 2019 8:16 am    Post subject: Reply with quote

yep I was considering similar, hardly the most complex of shapes and end of the day as long as its strong enough to jack the car on I couldnt give two hoots if it looks slightly different to original. I bought my 996 to drive not to keep as a garage queen concourse investment.
 
  
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rgracin
Newbie


Joined: 24 Jan 2014
Posts: 36



PostPosted: Thu Nov 14, 2019 9:17 am    Post subject: Reply with quote

Looks like some great work there.

I'd be interested in how you did the arch. Any more pictures?
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2000 986 Boxster S
 
  
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stichill99
Nürburgring


Joined: 03 Nov 2013
Posts: 410
Location: Scottish Borders


PostPosted: Thu Nov 14, 2019 9:50 am    Post subject: arch repair. Reply with quote

I would love to see more photos of the arch repair aswell. Why did you step the panel instead of butt welding? Is that not just making a water trap?
 
  
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