ButtSled

After replacing the reservoir, clutch master, hose, slave and everything but the clutch, I finally found why my pedal will not return properly. Yes the dreaded cracked firewall. Now my car is a boat anchor and I am very concerned about welding in that area. My car is an 83 944 and except for this problem is electrically and mechanically "perfect." Does any one know where in Houston might be qualified to tackle this problem? Any listers got a welder and some desire to help out a brother? I would almost rather do a complete clutch job by myself rather than dissecting my electrics and firewall to facilitate welding. AAAArrrrgggghhh. But that looks like what has to be done. Please let me know of your fixes problems and most importantly any mistakes made when doing this repair. Many thanks in advance.

Dean Felton
Hoston,TX
Owner of beautiful black German steel statue.

potent951turbo

I just finished fixing the same problem on my 951. A fellow lister came to my house and welded it up for me. I ended up having to pull the fuse box, and then the entire harness out through the hole near the clutch master cylinder. I also pulled back the sound proofing and put towels in between that and the body to help hold it out of the way. We welded it inside and out, and I grinded it smooth with my dremel and put some galvinized primer on it along with some sealant and paint and now you can hardly tell anything was done.

Zero10

Wow, I brought up this same topic earlier this week...
Happened to a friend of mine's car.

2bridges

hey buttSled - althought this is a bummer... not that huge of a deal. If you get it prepped ( everything out of the way wiring, plastic, carpet etc) pulled away 8-10" from where to weld anybody with welding skills should be able to take care of that. wet towels are good idea inside too.

Any welding shop could handle this.... just have to transport the car to them once prepped.
Also make sure you (or somebody) is in car ensuring no fire

LAST TIP - IMPORTANT! Always disconnect battery before welding on car.

ButtSled

Ouch!

2bridges

yeah, no love.

I would fab a plate and spot weld to it as well..... a tight spot to weld in

fezz

i've seen this a couple of times at my local shop.

the last one I saw required the fuse harness to be cut and respliced.
body shop welded in new section from donor car. the work was excellent.
Not surre how much it cost, though.

Mike C.

Might it be possible to secure it with blind rivets?

ButtSled

Had a welder come by Sunday and got that biotch sorted. We made a template and slapped an 1/8 plate in there and welded and bolted it on. It uses the existing studs and doesn't mess with the booster or wiring. (too much.) I made a copy of the template and I will try to scan it actual size and get it posted for all to consume. I do so love over-engineered things. The car will rust away before this plate does. Used some leftover 3m window weld to seal all the holes and seams and lots of por 15. Many thanks for all the input and support.

Best Regards,

Dean Felton

devious944

how does that happen?

2bridges

GOOD FOR YOU DEAN!
I am glad you did not let that scare you off the car....... like most things if you just get afterit, usually works out just fine.

ButtSled

This is the outside before the repair. Very scary.


Dean Felton