Front End Rebuild Project

[78F350]

It can be removed and replaced. I just scrapped a car that had the whole front end intact. I think that you or a body shop can find a front tub in Toronto that could be parted. The skilled labor hours are probably what make it impractical.
My old factory service manual "Group 5, body" has instructions:

[9864ever]

This is great thank you. Since the tub looks to be ok, based on the diagram it looks like Part A is what I need and maybe the left side could be pulled back into shape. All the damage was above the frame rail - then again, it needs to be checked.

There's a 986 in Toronto being parted out so might be an opportunity. Would you know if the rivets on these cars are hardened or can they be drilled out? Not sure if they'd sell just this one piece or if i'd have to buy the whole shell.

Luckily I might get some help from a good friend who owns a car dealership and has a bodyshop that he does a lot of work with.

[78F350]

Originally Posted by 9864ever

... There's a 986 in Toronto being parted out so might be an opportunity. Would you know if the rivets on these cars are hardened or can they be drilled out? Not sure if they'd sell just this one piece or if i'd have to buy the whole shell. ...

The sheet metal panels are spot welded and sealed. The welds can be drilled and welding the new part on fills the holes.

I think that it would be best to have the shop/person that is repairing your car have the whole front of that parts car. That way you know that the parts are removed complete and correctly.

DFreswick has some pics in his for sale thread that might help you visualize the construction of the front:
http://986forum.com/forums/589208-post115.html

I can probably scan and email a few pages of the manual if you need to see any particulars. I don't like to post too much of it directly

[9864ever]

Originally Posted by 78F350

The sheet metal panels are spot welded and sealed. The welds can be drilled and welding the new part on fills the holes.

I think that it would be best to have the shop/person that is repairing your car have the whole front of that parts car. That way you know that the parts are removed complete and correctly.

DFreswick has some pics in his for sale thread that might help you visualize the construction of the front:
http://986forum.com/forums/589208-post115.html

I can probably scan and email a few pages of the manual if you need to see any particulars. I don't like to post too much of it directly

That would be great if you don't mind! I will send you a PM so you don't have to post it here.

[itsnotanova]

To me, that doesn't look too bad. Sure the fender is trashed and the part that the fender attaches to is bent, but the main frame rails are untouched. A slide hammer, body hammers, variety of hand tools, some heat and that panel would be back to usable condition quickly. As long as you got the mounting area straight, no one would ever be able to tell unless you told them. Even then they'd have to pull back the trunk liner to really see. On another note, if you do decide to part it out those 2003-04 3.2's are gold. You'll probably get most of your money back with just the engine.

[9864ever]

Originally Posted by itsnotanova

To me, that doesn't look too bad. Sure the fender is trashed and the part that the fender attaches to is bent, but the main frame rails are untouched. A slide hammer, body hammers, variety of hand tools, some heat and that panel would be back to usable condition quickly. As long as you got the mounting area straight, no one would ever be able to tell unless you told them. Even then they'd have to pull back the trunk liner to really see. On another note, if you do decide to part it out those 2003-04 3.2's are gold. You'll probably get most of your money back with just the engine.

Thanks for the input Woody. I really do want to save it but want to do it right too. Initially I thought the same by just pulling back into place but 78F350 convinced me that replacing some of the structural panels is the way to go.

I'm currently looking for a donor and just missed out on a full front clip that was sold locally. Checking to see if the parts can be bought separately online.
This is the actual car prior to the accident - Paul's Car Care - 2003 Porsche Boxster S

[itsnotanova]

That's cool. I like doing body work and I'm pretty good with metal. I took a year of autobody in high school and I've been doing it as a hobby for the last 30 years. It's really not that hard and kind of fun. I'd rather paint a car than have to rebuild the motor. I rarely flip porsches as there's more money in the parts. I bought this one with very similar damage as yours. It had more damage in the front but less on the side/top. I took it from this



To this in 3 hours.

I sold it to a friend's 18 year old son and they finished the painting to this.

A year later and now it looks like this

[78F350]

Originally Posted by 9864ever

Thanks for the input Woody. I really do want to save it but want to do it right too. Initially I thought the same by just pulling back into place but 78F350 convinced me that replacing some of the structural panels is the way to go. ...

Just to note: Woody knows a lot more about this stuff than I ever will and I value his advice above mine. The thing about it is that in a case like this, he could spend an hour with a slide hammer and make more progress than I could in a week. He may not realize that not all of us have his skills.

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