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My 996 C4S Project

Jay Kay said:
Lovely looking car, colour really suits it. I am considering my first 911 the not too distant future but I don't think I'm brave enough to take on that level of work! I hope you got it super cheap
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Well, I quite enjoy getting my hands dirty, but yes, I accept it's not for everyone! It was pretty cheap - as mentioned above, it was the cheapest C4S manual on Autotrader, and then I got a fair bit of money off.


JGriffter said:
Good luck and enjoy the journey.
So what's your wife going to do with all her free time over the next 12 months?!
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Thanks, definitely going to need a little luck! My wife will probably be spending the free time driving her 986 now I 've got it sorted! :D

toddy2 said:
Looking good. Mine needed a similar amount of works and still does!

How are you getting on with the front diff leak and RMS leak? I have the same issues, any idea on what you're budgeting for these?

Good luck in your restoration...
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Thanks! With regard to the RMS, the oil level isn't dropping much when I drive it, so I'll probably leave it until new clutch time. The front diff leak is probably ('Probably'!) the seals. These are about £25 each from my local Porsche dealer, so I'll try fitting new ones and see how I get on!
 
ProjectC4S said:
Coffin arm /tuning fork /wishbone assembly is clearly shot. I think I'll just replace all the front suspension at the same time!
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Spider Performance do a complete set very good price.
 
...one word...BRAVE...

...the mechanical bits wouldn't worry me too much but the rust...sorry been there and done that...never again...

...good luck buddy :thumbs:
 
GMG said:
...one word...BRAVE...

...the mechanical bits wouldn't worry me too much but the rust...sorry been there and done that...never again...

...good luck buddy :thumbs:
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Ha ha, yeah, I'm learning about rust treatment. Maybe I'll decide it's not for me either!

Anyway, first easy jobs are now done. I've replaced the windscreen wipers and the bonnet gas struts. At least the bonnet won't fall on my head any more. That bloody hurt. I don't really understand why the car had £2,711 worth of work done literally 11 days before I picked it up, but the wipers don't clean and the bonnet falls on your head. Still, done now. I used the Porsche special tool piece of wood to keep the bonnet open whilst changing the struts. This specialised and expensive tool is available to hire now for only a small fee.
 

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I've picked up these as well to guide me through the jobs that are more difficult than changing wiper blades. The support for Porsches available in books and online is just incredible.
 

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I've now received big boxes of parts from Frazer Part and Design 911, as well picking up some more parts from my local Porsche dealer. Next is to start stripping the front suspension! The C4S doesn't look too out of place among the Taycans and 992s!
 

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So, from Frazer part, we have:

New TRW steering tie rods (inner and outer)
New hand brake shoes
New front drop links

From Design 911:

New front shocks
New coffin arms for front and back
New diagonal 'tuning fork' arms for front and back
New bump stops and bellows for front
New top mounts and bearings for front shocks
New front anti roll bar bushes
New track control arms for rear
New Brake hoses

From Porsche:

New front anti roll bar
New anti roll bar brackets
New Front brake lines (at wheel)
New Front brake lines (pre-hose)
New front diff seals
New front springs
New front brake shields

I've also scrounged various bolts, nuts, washers and jubilee clips from the Machine shop I work in. That'll all keep me going!

Also, I decided to just delete the inoperative rear wiper. I never use those anyway. Not to everyone's taste I know, but I prefer the look.
 

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Wow! This looks like a great project :-)

Like someone else said, I have no problems changing parts etc...but rust :o :o

What about coils, plugs, engine mounts, gearshift linkage?

It'll be a completely different car when it's all done! :D
 
photek said:
Wow! This looks like a great project :-)

Like someone else said, I have no problems changing parts etc...but rust :o :o

What about coils, plugs, engine mounts, gearshift linkage?

It'll be a completely different car when it's all done! :D
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Cheers! It's entirely possible I've bitten off more than I can chew here. It's certainly the biggest car project I've taken on! Regarding the rust, my plan is to do all the rust in the wheel wells myself - if it doesn't look perfect, no-one will see it. The visible rust I might get professionally done, haven't decided yet.

The plugs were done at the big service 11days before I picked it up and whilst the coils aren't new, don't look terrible. Engine mounts were done a few years ago, so also not urgent. The gear shift is... OK. It'll need an overhaul at some point, but unlike the suspension isn't making dangerous sounding noises. Suspension is definitely the priority!
 
Great project!

I am kind of shocked on the amount of rust, never seen this on a 996 before (at least in the Netherlands not, maybe you have more salt on the roads during winter?)

Keep the updates coming :thumb:
 
Goofy said:
Great project!

I am kind of shocked on the amount of rust, never seen this on a 996 before (at least in the Netherlands not, maybe you have more salt on the roads during winter?)

Keep the updates coming :thumb:
Click to expand...

So, we are pretty notorious for the quantity of salt used here in the UK. Apparently when Hyundai first started selling here, they assumed their UK reps had a decimal point in the wrong place when they told them how much salt was used on the roads. They then had to massively increase the amount of underseal when they realised! No idea if that story is true, but it makes the point.

What could also be a contributing factor is that according to my under bonnet sticker, is that this is actually a Cyprus/Malta car rather than a UK car. It was quite common in the late 90s / early 2000s for new cars in the UK to be sourced elsewhere as it was quicker and cheaper. Cyprus/Malta cars are RHD, but may have less robust anti-rust sealing. Again, no idea if there's actually any difference, but It's possible. My wife's UK spec 2003 Boxster is completely spotless by comparison.
 
I had a couple of hours free and decided to have a go at sorting the weak handbrake. I'd assumed that it just needed the shoes replacing. However, I opened it up to find plenty of meat on the shoes. I then tried adjusting the cables to check those, but found that one side was completely jammed. Turns out the hand brake had been operating on one wheel only! It really needs properly sorting by replacing the cables and guide tubes that feed into the rear hubs. As a short term fix though, I squirted lots of WD40 into the cable tubes from both ends and managed to free up the cable. I now have a properly working hand brake! The full fix will have to come later. You can see in the photos below the hand brake shoes with plenty of material and the poor condition of the guide tubes.







[/img]
 
It's been a long time since I posted here, although plenty of work has been going on. I'll post up pictures and descriptions in order though. First up, I started the major work on the front axle. All lower arms, struts and front brake callipers have been removed. I think the car might be on axle stands for a while..!
 

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Here's one of the old struts removed from the car. It's a hell of a state!
 

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Here's the strut disassembled. I'm going to re-use the spring carrier, 'Compensating Plate' and the two concave washers on either side of the top mount. Everything else is being replaced.
 

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