Ger's 2003 Porsche Boxster S

[TrumpyAl]

My new method will look a lot like what's used in this video...

http://youtu.be/n_7dW3g6Xqw

Hope I don't burn my house down.

[geraintthomas]

You need to make the hole a little bigger with a dremmel and get rid of the notches for the lens to sit flat, but yeah it's very similar.

It's just opening the lens. I can't close the oven door with the headlight in as it won't fit, and leaving the oven door open will loose too much heat. I'm not buying an oven just for this job (even if it is a scrap one), and apparently I can't use a heat gun.

This is looking less likely by the minute

[jdraupp]

Ger, remember that heat plays a big part in a lot of things. It expands things. I had a Nissan that had a leaking head gasket. It would run rough when cold, then heat would expand the gasket and seal it and it would run perfect again. I'm guessing some variation of this is happening to your exhaust headers.

[TrumpyAl]

I thought the cardboard box being used with a heatgun had promise? To date I've only ever needed a heat gun but I like the approach he uses in the video better.

[geraintthomas]

Originally Posted by jdraupp

Ger, remember that heat plays a big part in a lot of things. It expands things. I had a Nissan that had a leaking head gasket. It would run rough when cold, then heat would expand the gasket and seal it and it would run perfect again. I'm guessing some variation of this is happening to your exhaust headers.

But that's what made me think that it wasn't an exhaust blow, because it happens when hot and not cold. But I suppose leaks and cracks could expand.

I'll have a little look to see if I can see anything myself, but I can't imagine I'll be successful. I'll take it to an exhaust garage whenever I get time.

Originally Posted by TrumpyAl

I thought the cardboard box being used with a heatgun had promise? To date I've only ever needed a heat gun but I like the approach he uses in the video better.

Heating a cardboard box to 225*C? Not sure I could do that...

[TrumpyAl]

Your source (particleweave), used 225 Fahrenheit, not Celsius in this video?

http://986forum.com/forums/diy-project-guides/51565-how-open-sealed-headlight.html

His 'old' video lists it as 225F which makes sense seeing as he's in the US.

So maybe double check with him? I can't claim to have done it myself and they certainly aren't sealed with Butyl rubber which is all I've worked with to date, so don't take my word for it

[geraintthomas]

Oops. That'll be about 107C then. Still bloody hot!

The only other way I can think of doing it is to use a heat gun from further away for a longer amount of time, so that it's not direct scalding heat but heating it gradually.

[geraintthomas]

Exhaust blow has been fixed gasket between the header and the cat. The mechanic replaced both gaskets to be sure on both sides, and replaced a few corroded U-clamps on the back box. Did the whole thing for £30, cash in hand. Very happy!



Sounds better than it ever did, it must have always had a slight blow.

All that's left to do now is to fix the drivers window regulator that snapped a few days ago, and the car's back to normal. £80 for the regulator unfortunately but it's not the end of the world. Could be worse.

[geraintthomas]

--Duplicate post--

[TrumpyAl]

Awesome result!

[JayG]

Nice! Always great when its a low cost repair
Unfortunately it will cost you a lot more to get the steering wheel moved to the correct side

Cheers

[geraintthomas]

So gave the car a good clean a couple of days ago...





Aaaaand how it was when I woke up this morning:



Practically a bloody ice cube!

[paulofto]

Originally Posted by geraintthomas

So gave the car a good clean a couple of days ago...
aaaand how it was when I woke up this morning:



Practically a bloody ice cube!

Well being so clean the coating of frost is nice and even!

[geraintthomas]

Hopefully this Saturday I'll have time to fit the new window regulator so the car can be completely back to normal. Sunday I won't have time as I'm going to pick up some new 18" cayman wheels! Wooo!

Anyway - I've updated my to-do list for the car:

[geraintthomas]

Some updates!

Window regulator has been fixed, all back to normal now. The window doesn't seem to drop as far as it used to but it doesn't catch on anything and is still a perfect seal, so no complaints there.

I've bought some new number plate LED's but Cree ones this time. One of my bulbs has gone so it's time for a change.

I've bought 4x Cree LED indicator bulbs, as well as a replacement relay for the flasher. I had these bulbs on my Celica and they're outstanding. Very bright, instant on and off, modernises the car to no extent.

And, I've just bought these from a forum member:



Putting them on today! Great guy, had a good chat and I'm really pleased with the wheels

I'll post photos of the wheels on the car later, but it may be dark!

[geraintthomas]

And on the car:





So much better. Also bought these:



Comparing it to the old ones:



And on the car:



Freshened it up!

These also came in the post.

Cree number plate bulbs:



Left one is the old LED, the right is the new Cree LED:



And both in:



Some Cree LED indicator bulbs also came (4 in total):



And a relay to make them work:



I tried the bulbs. They're outstanding, but unfortunately the relay didn't work so I've bought resistors to place onto each bulbs wiring to make them work.

That's it for now!

[particlewave]

Those wheels are a great fit on the 986. I'm jealous!

[TrumpyAl]

Agreed - the wheels look great. I was thinking that the old ones looked pretty good, but the new ones are much better.

Those centre caps are a nice touch too.

[grc0456]

A nice look on the 986 with those wheels. I love wheels of all kinds and I think all of the Box's wear them well!


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[geraintthomas]

Thanks guys, appreciate it