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How to remove a fender.

 
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924guy  



Joined: 29 Dec 2003
Posts: 2088
Location: Port St. Lucie, FL

PostPosted: Wed Oct 25, 2006 8:55 am    Post subject: How to remove a fender. Reply with quote

SO i had to yank my fenders off, so i figured i might as well take some pictures and hopefully make someones elses a project a bit easier..

Tools:

Metric sockets set, long and short 10mm socket assortment can make life easier, as will a set of long extensions.
Rubber mallet (to tap in wedges to break adhesive seal)
razor knife of some sort, the longer handle the better, but should have an angled blade, a flat blade wont do it. i just used a box cutter.
an assortment of long and short shanked flat head screw drivers or short handled pry bars
a heat gun (under $20 at harbor freight or other stores)
couple of shop rags
a pair of leather gloves (especially when using the heat gun)
shop goggles.
drop light or flash light

get your 924/944 and pop the hood (gratutious pic of my car "before" follows)

http://pg.photos.yahoo.com/ph/my2porsche/detail?.dir=949e&.dnm=21c9re2.jpg&.src=ph

remove the 10 mm bolts along the hood rest channel, and the rubber dampers. use a small screw driver to pop these up and out from underneath, if your lucky, theyll come out in one piece and not split. mine had a 50% mortality rate.
http://pg.photos.yahoo.com/ph/my2porsche/detail?.dir=949e&.dnm=d6f7re2.jpg&.src=ph

Disconnect your battery (recomended) or unplug the power at the head light motor, then using the know behind the rubber cover at the rear of the motor, raise your headlights fully.
http://pg.photos.yahoo.com/ph/my2porsche/detail?.dir=949e&.dnm=1455re2.jpg&.src=ph

http://pg.photos.yahoo.com/ph/my2porsche/detail?.dir=949e&.dnm=33e1re2.jpg&.src=ph

pull out the rubber seal at the front of the headlight housing, it just pulls out (towards the rear of the car) and unscrew the 10 mm bolt hidden in the out board corner.

http://pg.photos.yahoo.com/ph/my2porsche/detail?.dir=949e&.dnm=62eere2.jpg&.src=ph

Turn your steering wheel to full lock, this will put your tire/wheel well out of the way, so you can get to the three bolts that hold the front bottom of the fender to the front spoiler and support bracket. you may want to pull off your front bumper as well (unplug the lights, unscrew the four bolts at the support arms is usually easiest) for better access, these bolts will covered with sealant, and its tough to get a wrench over them without some scraping first.
http://pg.photos.yahoo.com/ph/my2porsche/detail?.dir=949e&.dnm=6f5bre2.jpg&.src=ph

tip: use the heat gun to soften the undercoating, just use care as you can melt wires in the area or even light the undercoating on ifre with too much heat. use the heat gun like a hair dryer, in continuos motion over a broad area. the lump in the next pic is undercoating... Wear a mask and dont breath in the fumes this can create. I dont know whats in the undercoating, but it cant be good for the lungs. The leather type shop gloves come here as well, and allow you to handle the metal without being burned, as it will get fairly hot while using the heat gun.

http://pg.photos.yahoo.com/ph/my2porsche/detail?.dir=949e&.dnm=d29bre2.jpg&.src=ph

http://pg.photos.yahoo.com/ph/my2porsche/detail?.dir=949e&.dnm=b9eare2.jpg&.src=ph

http://pg.photos.yahoo.com/ph/my2porsche/detail?.dir=/949e&.dnm=c0b1re2.jpg&.src=ph

If your on the drivers side, youll need to pull the charcoal canister for the emissions system (if you have one) out next, its bolted in in two spots, at the top and at the bottom of the unit. their either 9mm or 10mm bolts. then remove the hose clamps (mine just crumbled away) and pull it out.
no such worries on the passenger side.

http://pg.photos.yahoo.com/ph/my2porsche/detail?.dir=949e&.dnm=ce4bre2.jpg&.src=ph

If youve got a power antenna, that will be behind the charcoal canister and must also be removed. remove the locking ring on top of the fender (where the antenna pops out of) then the two bolts that hold the antenna in , and then youll need to unplug or cut the coax and power leads, and pull it out.
http://pg.photos.yahoo.com/ph/my2porsche/detail?.dir=949e&.dnm=bce3re2.jpg&.src=ph
http://pg.photos.yahoo.com/ph/my2porsche/detail?.dir=949e&.dnm=c847re2.jpg&.src=ph

next youll need to remove the antenna mounting bracket, two bolts. the bottom bolt may be covered with undercoating and youll have to scrape it off it (heat gun helps) before you can remove it.
http://pg.photos.yahoo.com/ph/my2porsche/detail?.dir=949e&.dnm=36aere2.jpg&.src=ph

thats two of the three inner bolts, the third one is in line with the others, and up near the top body line, itll be burried in sealant, but its there.. above the scrape markes in the above picture, took me a bit to find it under all that sealant.

theres one more bolt a the bottom of the rocker area. if youve a 924 turbo, youll need to remove the lower trimand end caps. the end caps are simply plastic rivots, and will pop out easily by putting a small screw driver or nail through the center of the rivets. the trim actually has a bolt inside the fender to release it, but chances are itll be seized up and just spin. i just gave the trim a yank and it poped right off with no damage, your mileage may vary. then unbolt the last lower bolt.

http://pg.photos.yahoo.com/ph/my2porsche/detail?.dir=949e&.dnm=9007re2.jpg&.src=ph

now youve got all the bolts out, but its still going to be well stuck to the inner fender walls. carefully use your heat gun allong the body seams to loosen up the sealant thats holding it on. along the top edge, i used several screw drivers to wedge the fender up and away from the frame. dont pull to hard, the fender can and will easily bend.
http://pg.photos.yahoo.com/ph/my2porsche/detail?.dir=949e&.dnm=b4bbre2.jpg&.src=ph

along the door side, i used my box knife to cut the sealant down the seams, after softening it up a bit with the heat gun, this area was most difficult due to the amount of uncoating and grime there. i rocked the whole fender (not too hard, itll bend) to help it unglue itself, and eventually, it will come off.
http://pg.photos.yahoo.com/ph/my2porsche/detail?.dir=949e&.dnm=94edre2.jpg&.src=ph

schedule about three hours per fender. im sure it can be done faster, but take your time and dont rush, especially if your going to need that fender again..
Good luck!


next up; look for rust repair (hopefully you wont find any when you pull your fenders, i did then fitting a Carrera GT body kit...

http://pg.photos.yahoo.com/ph/my2porsche/detail?.dir=949e&.dnm=8bbcre2.jpg&.src=ph
_________________
Eric
78 924
82 931 SE "smokey"
99' VehiCross
Y2K Honda Insight
http://www.cardomain.com/id/924Guy
Performance by Pasha


Last edited by 924guy on Wed Oct 25, 2006 11:47 am; edited 1 time in total
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endwrench  



Joined: 07 Dec 2002
Posts: 1631
Location: Victor, Montana

PostPosted: Wed Oct 25, 2006 10:58 am    Post subject: Reply with quote

Hmmm, who 'da thunk it it would be such a PITA to get the fenders off one of these buggers! Can't wait to do the same.

Todd
_________________
'79 924NA. Rebuilt 9.5:1, MSDS header, Mega Squirt Injection, MJLJ-EDIS Ignition, 1.6L Whipple Charger and Intercooler, 10lbs Boost, 944 Trans, Custom HD Clutch.
"simsport" said....superchargers are better than turbos its official!....
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Zermatt924SUK  



Joined: 13 Dec 2007
Posts: 43
Location: UK

PostPosted: Sun May 04, 2008 1:06 am    Post subject: Reply with quote

Wouldn't mind Seeing the photos..as they're No longer available via these links...I'm attempting to take my Wing off..Thankfully I can destroy it to get it off as I'm Replacing it with a new one!
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924guy  



Joined: 29 Dec 2003
Posts: 2088
Location: Port St. Lucie, FL

PostPosted: Mon May 05, 2008 12:12 am    Post subject: Reply with quote

try here:

http://flickr.com/photos/924guy/sets/72157602664472665/detail/

yahoo photos converted everything.. i need to swap them over to image shack or something.. ill try to update them soon....
_________________
Eric
78 924
82 931 SE "smokey"
99' VehiCross
Y2K Honda Insight
http://www.cardomain.com/id/924Guy
Performance by Pasha
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Zermatt924SUK  



Joined: 13 Dec 2007
Posts: 43
Location: UK

PostPosted: Wed May 07, 2008 1:06 am    Post subject: Reply with quote

it says the Page is private...I'll check again later...
Thanks
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