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The quest to add lightness continued. I tried to shave a few pounds off the car each day.
With the Rennline radio delete plate installed, it seemed like a good time to delete the upper center console and move a few controls to the dash. I also began carefully removing the insulation out from underneath the RS carpet. The RS carpet was one of the best features of the car, but it was installed on top of the existing stock insulation. That largely defeats the purpose of an RS carpet, which is incredibly light. The plan was to carefully pull up as much insulation as possible without damaging the carpet. But as the project progressed, I decided to toss the RS carpet altogether and leave the car bare. All was going smoothly, but rust never sleeps. I had detected some rust under the driver footwell last summer. That one footwell had already had the insulation removed. I assume the insulation was water damaged. I didn't remove the make-shift wooden floor board completely, but there was some minor surface rust visible. With the floor board now out completely, and the pedal board out as well, the surface rust on the floor board was far more extensive than I had imagined. The pedal assembly was rusting as well. Thankfully it was just surface rust, so I got to work...
Radio Deleted, Insulation coming out
Stock insulation had not been removed despite the RS carpet
The insulation and glue were easy to remove here
The weight really adds up
Original plan was to retain RS carpet after removing insulation like this
Here's where things start to go sideways. The plan was to use a wheel wire brush and drill to remove the surface rust off the driver side floor board. Heck, I had already ordered a rattle can of paint from Touch Up Direct. Easy. But as I peaked under the rubber covering the center drain holeI, I discovered that the rust was far more extensive underneath. The rubber appears to have trapped the moisture from inside, and it was literally eating away at the car. And someone at the factory really loaded it on heavily when applying the rubber on my 964.
Armed with this realization that rubber was a breeding ground for interior rust, I began inspecting the whole car more closely. Sure enough, there was rust under all of the rubber on the floor boards. Worse, there rust on the rear seats. Heck, there's rust everywhere... The one saving grace was that I caught this in time, while it was still just surface rust. So it's grind, grind, grind the rust away.
Plan is to brush away the rust on the front floor board and do a quick touch up
Peaking under the rubber, it looks like more rust hiding underneath
The pedal cluster box and pedals look great after a fresh powder coat. I purchased new bushes and hardware and reassembled the pedal cluster. But the hole in clutch arm didn’t line up properly with the kinematic lever. It seemed like the clutch tube was 4mm longer than the original tube, but it’s the same part number! Hold the phone. It turns out Porsche messed up and mislabeled all of the clutch tubes now in stock in the US. They’re all labeled 964 423 069 00, but the part number stamped on the clutch sleeve is 965 423 069 00. That’s the sleeve for the turbo. It looks exactly the same but for the fact it’s 4mm longer.
New correct part en route now, from Germany...
Pedal assembly powder coated, all new hardware and bushes.
Clutch sleeve seems too long and hole doesn’t line up.
03-27-2018 | 02:08 AM
That’s the sleeve for the turbo. It looks exactly the same but for the fact it’s 4mm longer. 
