Gary Knox

Tony/Jerry,

Regarding "fitting out of the box" for the liners on Tony's GTS. I - as you both know - am extremely interested in the results of Jerry's work, and WILL be in attendance for any fitting trial. I'll either help (hinder??) or just observe, depending on Jerry's desires.

See ya' next weekend (sans Katrina, the GTS).

Gary

Jerry Feather

Well, I have been changing the outer half form a bunch of times since I got the GTS4 for fitting. I think I have made 4 major changes to it and just now finished the fifth, but it was only minor. What that actually means, I hope, is that I am very close to getting the last piece of these liner to fit like they should.

Here are some pictures of where I started today.

Last nite I had set up the drill jig to drill a fresh pair of halves that I blew yesterday, so I drilled it and then tried to get it to fit. As you can see there is some slip showing in the front and the wheel arch does not match very closely in the upper rear. The rear bottom also needs some tweeking. Too, the whole upper part needs to be formed a little wider.

The last of these pictutres shows basically what the liners will kind of look like, although in practice they will not be assembled like this except in the car and then you cannot see them in this view.

One good thing is that at least I was able to get the outer half in with most of the connecting clips installed. That was a first for this project.

Jerry Feather

Here are some more pictures.

What these show is that in spite of the thought that I am sure many of you have that I am screwing around way too long with this project or worse yet, not paying enough attention to it, here are some pictures of some of the attempts I have made at these liners, and all of this is basically waste. I haven't taken the time to clean up this mess and don't usually clean up but about once a year or so, even if it doesn't need it, and the year is not up yet. I will be taking all of this plastic back to the supplier and putting it in his recycle bin.

Every time I have to make a change in the forms it takes about 2 or more hours then another two or more to blow the plastic, trim it out, and see if it fits.

But, as you can tell by some of my other posts I have been devoting some of my time to other projects, but I find that that is pretty necessary just to help maintain some sanity.

Jerry Feather

I finally got an outer half that almost fits. This one shows that I can probably get all of the connecting clips to fit and the bottom front and rear are very close to what I want, and may stay that way. However the top of the wheel arch is still not tight and I don't have this one drilled very accurately.

Since these pictures were taken I have made the necessary changes to the form and will blow another set of outer halves in the morning.

Jerry Feather

nc_growler

Closing in on the finish line here Jerry. :-)

Schocki

Impressive! Good job, you're getting there !

Crossworth

Hi Jerry,

Outstanding job, clearly an act of devotion and patience. I got up to speed on your thread. Persistence pays. I am sure your are making a dream through for us, including me.

On occasion I see little bits of my liner on the garage floor. At least there is hope for a quality replacement unit.

I am looking forward to your unit that has the high density noise absorbing material.

Off on a slight tangent:

Speaking of wheel wells. I was at shop recently that had a 500 AMG on a car lift for brake service. The wheel liners was pulled to access the brake line fittings. I noticed the wheel liner was made out of special black foam material, at least thats what looked like.
Kinda odd ( IMO ) wondering if would survive the life of the car. Wondering if gets replaced as one the maintenance item on the Mercedes / AMG series.

At any rate swell Job !!!!
Any chance it will be arriving the San Francisco Bay Area?

Thank you

Jerry Feather

Hi Crossworth. The "if" about these arriving anywhere now seems to be getting very much smaller. I have been having my doubts about being able to make these work at all, but have refrained from posting about that on here. It hasn't so much been that I haven't been able to see how to do it, but rather the effort in continually making changes that then require other changes and then it has to be changed back in some way, has made me very frustrated to the point that I have had doubts about ever finishing up. If it hadn't been for the encouragement by all of you and the obvious need, I might well have given up some time ago; and I think many of you have thought that is just what I have done at various points over the last year and a half.

In any case, I think I am just about right there with the process.

As to availability, I am going to come up short of taking any extra prototype sets to OCIC, and will be lucky now to even take one set in my GTS4 and hopefully one set assembled out of the car for show and tell. The other two sets I was hoping to take for field testing are going to have to be finished up after the meet and shipped. Then at about the same time I am going to start GTS production.

As to "arriving" in SF, I plan to have these arrive anywhere in the world that they can be reasonable shipped. I now seem to have Wolfgang in Vienna interested and I know there are going to be some shipped to AU, so SF will be no problem.

Thanks for your interest, It always helps keep me focused when I hear from guys like you and many of the others.

Jerry Feather

mickster

Okay stupid question of the day...

I have a '91 S4. Can I fit/retrofit earlier MY rear fender liners?

Rob Edwards

Michael-

Yes, here are two threads with pics and part numbers. Whenever Jerry's liners are available I'll make you a deal on my lightly used liners. But then, Jerry will have rendered them unnecessary.

https://rennlist.com/forums/928-foru...make-them.html

https://rennlist.com/forums/928-foru...er-needed.html

Bill Ball

I dealt with the PSD in a 93 GTS yesterday. The liner had the structural strength of very thin, flaky pie crust. There is no way it would have survived removal. Pieces began to chip off just from touching it. We had to do everything through the small PSD reservoir viewing door, and the area that fastened to did not survive. Gobs of RTV we applied may hold that piece on for a few miles. What a total piece of crap, but you all know that.

dprantl

No, I am positive that it is hardened candle wax.

Dan
'91 928GT S/C 475hp/460lb.ft

Gary Knox

YES - Dan, hardened candle wax is the best description I've heard of the material in the fender liners.

When I removed the left rear one after purchasing the '94 six years ago to service the PSD I wasn't sure it would survive re-installation. For the most part it did, but I used S4 F & R liners for that wheel well on top of the OE GTS one to both protect the areas and firmly hold the upper part in place.

When I removed it to service the PSD this winter after 20K miles, I decided to "bet" on Jerry's success, and threw the 5 or 6 pieces that were laying on the floor away.

I can't imagine that ANYONE at Porsche or at their supplier ever "use tested" these in accelerated aging tests before specifying that material.

Gary--

Gary Knox

Jerry,

I hope you were pleased with the interest in your wheel well liner projects (and demonstrated results) along with the cowl insert and the "noise reducers" for the windshield on non-GTS's at OCIC. I assisted in installing the right side wheel well liner during your demonstration and was VERY impressed with both the fit and ease of installation. You said you had a bit of fine tuning to do before you'd have it ready for production, but I thought it was "darn good" at that demonstration.

Looking forward to hearing more.

Cheers, and thanks for all you are doing for all us 928 guys.

Gary--

pcar928fan

I just put Jerry's cowl piece in today! Great easy fit and looks like it belongs on the car! Thanks for a great product Jerry. I have not put the spare tire cover to use yet, but I got that in the mail today as well! Super fast shipping by the way!