993 chassis leg repair experiences and pictures
Discussion
Hi All
I thought I’d quickly post some pics of the recent chassis leg repairs to my 993TT. Most owners of 993’s probably know about this area, but for those that don’t its definitely one to have checked. I only did this because the engine was already out for some work (improvements in output ;-) )
The issue is the flat plates attached to the chassis leg behind the rear lights (I think these are called bumper or wing support plates, someone will no doubt post the correct terminology for me).
The pic below shows the plates (post repair)
Originally these plates were bolted to the chassis legs, then some sealant was run around the gap between the plate and the chassis leg, and then the whole lot was painted.
The issue is that if the sealant wasn’t applied perfectly or has aged, water sits on top of the plate and then finds its way down the gap to the unpainted/unprotected metal in between.
The plates on mine looked fine, and there isn’t rust on the rest of the car in any the usual areas (scuttle etc.), but when they were removed it revealed this:
Some cars are probably worse than mine, some probably much better (guess it depends on the guy on the production line who applied the sealant and how much the car has been driven in the rain).
Unfortunately to check requires the removal of the bumper and lights (although I guess it may be possible with them on?), and then removal of the exhaust boxes, the heatshields, the rear bumper stay and finally the plate (since although it may look fine from the outside, it is the metal in the gap behind that’s an issue).
Anyway onto the repair...
The rust was cut back to good metal on both sides, and then a new plate hand formed out of 18 gauge steel.
This was plug and seam welded and the the whole area etch primed:
Then it was first sealed and then painted body colour (this is the sealer before painting):
The new plates, were also separately primed, sealed and painted.
Finally the plates were bolted on (but now the metal in the gap between is protected by sealer and paint on both surfaces), and a bit of cavity wax applied to the chassis leg and ontop of the gap (the white stuff).
Will hopefully keep corrosion at bay for a few more years and definitely better protected than it was from the factory. Eporsch Colour who did mine say that they will check anyone else’s 993 (disassembly and reassembly) while they wait / watch (6ish hours) for £200 but I’m sure there are lots of people who can do this too.
Hope its been helpful.
Steve
I thought I’d quickly post some pics of the recent chassis leg repairs to my 993TT. Most owners of 993’s probably know about this area, but for those that don’t its definitely one to have checked. I only did this because the engine was already out for some work (improvements in output ;-) )
The issue is the flat plates attached to the chassis leg behind the rear lights (I think these are called bumper or wing support plates, someone will no doubt post the correct terminology for me).
The pic below shows the plates (post repair)
Originally these plates were bolted to the chassis legs, then some sealant was run around the gap between the plate and the chassis leg, and then the whole lot was painted.
The issue is that if the sealant wasn’t applied perfectly or has aged, water sits on top of the plate and then finds its way down the gap to the unpainted/unprotected metal in between.
The plates on mine looked fine, and there isn’t rust on the rest of the car in any the usual areas (scuttle etc.), but when they were removed it revealed this:
Some cars are probably worse than mine, some probably much better (guess it depends on the guy on the production line who applied the sealant and how much the car has been driven in the rain).
Unfortunately to check requires the removal of the bumper and lights (although I guess it may be possible with them on?), and then removal of the exhaust boxes, the heatshields, the rear bumper stay and finally the plate (since although it may look fine from the outside, it is the metal in the gap behind that’s an issue).
Anyway onto the repair...
The rust was cut back to good metal on both sides, and then a new plate hand formed out of 18 gauge steel.
This was plug and seam welded and the the whole area etch primed:
Then it was first sealed and then painted body colour (this is the sealer before painting):
The new plates, were also separately primed, sealed and painted.
Finally the plates were bolted on (but now the metal in the gap between is protected by sealer and paint on both surfaces), and a bit of cavity wax applied to the chassis leg and ontop of the gap (the white stuff).
Will hopefully keep corrosion at bay for a few more years and definitely better protected than it was from the factory. Eporsch Colour who did mine say that they will check anyone else’s 993 (disassembly and reassembly) while they wait / watch (6ish hours) for £200 but I’m sure there are lots of people who can do this too.
Hope its been helpful.
Steve
Ok, heres the long story, you asked for it!
Local Porsche approved bodyshop finally agreed to replace LHS sill and do a glass out repaint on the LHS quarter panel in 2010 under the repair scheme warranty. (this was after me taking it back several times previously - the original minor scrape was in 1999!)
While we looked round the car, I decided to get them to quote for attending to various age related issues: Door check straps; rear bumper supports; heatsheilds; windscreen surrounds, and the other sill, etc, etc,etc so eventually we agreed a full strip down and glass out restoration...
Turned out a bigger job than expected (doesnt it always!)because as well as the other stuff they found the chassis legs etc a bit iffy as per the OPs, and by that time I'd stopped counting the cost so just said sort it!
So that was it, April 2010 they took it in, and I got it back (the first time!) in July. The longer story is: I wasnt happy with various aspects of the finish/attention to detail and it has been back several times over the course of the next 2 years: Autumn 2010; Summer 2011; Summer 2012!
Ultimately, they got it right though, in fact it looked so good that in December 2011 I was kindly invited by the main dealer to put it on display in the 911 Evolution line up at the 991 launch...
However, that didnt stop me taking it back again last year to have the originally repaired wing and sill re-painted yet again under the warranty!
Rest assured, each time I wash or polish it, I always go through it all with a fine tooth comb, after all, the whole car has now been repainted and is under warranty for life!
edited to add photos
Local Porsche approved bodyshop finally agreed to replace LHS sill and do a glass out repaint on the LHS quarter panel in 2010 under the repair scheme warranty. (this was after me taking it back several times previously - the original minor scrape was in 1999!)
While we looked round the car, I decided to get them to quote for attending to various age related issues: Door check straps; rear bumper supports; heatsheilds; windscreen surrounds, and the other sill, etc, etc,etc so eventually we agreed a full strip down and glass out restoration...
Turned out a bigger job than expected (doesnt it always!)because as well as the other stuff they found the chassis legs etc a bit iffy as per the OPs, and by that time I'd stopped counting the cost so just said sort it!
So that was it, April 2010 they took it in, and I got it back (the first time!) in July. The longer story is: I wasnt happy with various aspects of the finish/attention to detail and it has been back several times over the course of the next 2 years: Autumn 2010; Summer 2011; Summer 2012!
Ultimately, they got it right though, in fact it looked so good that in December 2011 I was kindly invited by the main dealer to put it on display in the 911 Evolution line up at the 991 launch...
However, that didnt stop me taking it back again last year to have the originally repaired wing and sill re-painted yet again under the warranty!
Rest assured, each time I wash or polish it, I always go through it all with a fine tooth comb, after all, the whole car has now been repainted and is under warranty for life!
edited to add photos
Edited by Boo152 on Friday 8th March 17:43
The OP was really useful but Jackal did an even more in depth report & pictures on his site www.jackals-forge.com so it's worth checking that out too to see the job from a (fastidious) DIY perspective.
Nicely done OP. Thats a good colour as well .. arena red ?
Thx Goose, my article is only for the brave though, you need a few hours and plenty of coffee
full link: http://www.jackals-forge.com/lotus/993/chassisSupp...
Thx Goose, my article is only for the brave though, you need a few hours and plenty of coffee
full link: http://www.jackals-forge.com/lotus/993/chassisSupp...
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