Well I promised you it wouldn’t stop, the work continues.
Door cards were needed, mine are water damaged. I set about a repair with fibre glass tissue. First of all the foam buffer pads needed removing, following this I removed all the fluffy card with a wire brush and stanley knife. This was more of an experiment, as what I really need to do is remove the skin and sort out the water damage between the skin and hard board.
But this will give them some rigidity for the mean time.
I applied some weight, along with some packing inside the door pocket to try and correct the shape.
Fast forward some steps, water proof membrane installed. Foam padding installed as per factory. New door lock tell tails and securing clips. Everything cleaned with a tooth brush.
Obviously process repeated on the other side. Lets look at small details now.
A nice feature of the 944 is that if you open a door, not only does the interior light come on, but if you have forgotten to close a window, there is no need to put the key back in. A relay energises and sends power to the window motors so you can operate them. Just days after getting my car on the road this relay crapped itself. I bought a replacement, its a later spec with a higher current rating. But it was missing is mounting clip.
I moved the clip over, used some solid rivets and then fitted behind the dash.
Another super fun issue was just 4 days after the MOT. I arrived back at the car while out, it would spin over with out issue. But not a hint of life. It took me 10 minutes to remember my common 944 faults, but then the penny dropped. Check the DME relay, I used some wire wrapped around 3 terminals and plugged it back in.
The car immediately sprung back to life. When I got home the grey matter, wouldn’t let it rest, I was sure I had a new replacement and couldn’t work out why it wasn’t fitted. Sure enough I found this in the loft.
I installed this and its run perfectly ever since. It actually feels smoother, so I assume that relay was failing intermittently while the car was running.
One more little job for you, the light switch should be back lit. Fortunately mine just needed a new bulb, rather than any more serious work.
I must say by this point, it was nice to be working at a more relaxed pace and enjoying it. Rather than busting my balls to get it done. And of course if I ever got fed up, I could just go for a drive!
Were going to flit about here as I work though jobs that suited my mood on the day.
Adjusting the front wing and spoiler brackets.
Lets have a few money shots shall we. I had been suffering with a common issue. The Dansk rear section of exhaust was touching the rear anti roll bar under certain conditions. This made a very violent noise in the cabin. Which of course was not aceptable. As this was an issue I solved years ago, I can only assume when I welded the over sized tube onto the down pipe, I didnt quite get it parralel with the centre of the car. I used the 4 post at work to have a play.
The centre section was just touching the heat sheild.
Before I dropoped it, there was only a couple of mm gap here.
I opened up these hangers to drop the rear of the silencer a couple of mm in an attempt to give some more roll bar clearance.
This worked, at least it did at the start. but 100 miles later the noise returned. I spent some more time working on the alignment and it seemed to fix it. But a noise would still come and go under certain conditions. So I often pondered this and returned to my original conclusion, I would have to cut and weld the exhaust again.
That would be for another day though.
I coninuted to use the car, aiming for 1000miles worth of shake down.
On a run back from Leeds I called in at Tesco. Everything had gone very well, a nice smooth 50 miles. Only for the car not to start when I got back in. The starter was dead, I had just been admiring how geat the car was looking too.
A quick look underneath revealed that the trigger terminal from the solenoid had fallen off. Some how!? Luckily it wasnt raining and I had a screwdriver in the boot. So ignition on and I bridged the contacts with the blade. She sprung back to life.
Inbetween all this fun, I had started fitting various bits of trim. Well actually id been rubbing down and painting.