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964 C4 light refurb

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Old 03-02-2024, 06:22 PM
  #1666  
John McM
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It’s close to a year since my last post. Life got in the way of using the 964 so it sat quietly in the corner of the garage. However, I have a 2,000 mile road trip planned and it was time to recommission the car for the road.

In New Zealand, any car manufactured prior to 2000 requires a six monthly check called a warrant of fitness (WOF).

Without a valid WOF, the car can’t be licensed for road use.

I’m not anti safety per se but some of the rule changes rankle. For example, cheap aluminium wheel nuts ex China for boy racer cars have led to a ban on aluminium wheel nuts. Try explaining to some muppet that the 964 has had aluminium wheel nuts for 34 years and you get a blank stare.

In any case, I got my WOF. The only issue was my LED fog lights being permanently on. However the mechanic did note that my suspension clicked towards full lock and he could feel it through my strut top hats. In fact you could see the rubber twisting. That had to be fixed.

Last edited by John McM; 03-02-2024 at 08:53 PM.
Old 03-02-2024, 06:32 PM
  #1667  
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Given I had changed the struts in late 2022, it was a reasonable assumption that I had stuffed up, and I had.

The issue is part #3. If you don’t put it in the sequence in the diagram, you don’t give the strut room to rotate. Instead, it binds up with the top hat.

The critical part is #3

Spring retainer hard up against the strut top hat. When you turn the wheel, the strut binds and tries to turn the strut top hat.
Old 03-02-2024, 06:34 PM
  #1668  
John McM
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This is the WRONG place to put the washer
Old 03-02-2024, 06:35 PM
  #1669  
John McM
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This is the CORRECT place to put the washer
Old 03-02-2024, 06:37 PM
  #1670  
John McM
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This is how the strut gap should look like. The difference in steering is night and day. I’m not sure why I didn’t notice. BTW I incorrectly did both sides.


Last edited by John McM; 03-02-2024 at 06:38 PM.
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Old 03-02-2024, 10:35 PM
  #1671  
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LOL about the nuts.
Good catch on the washer. And being consistent is important....I guess even if its a mistake!
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Old 03-04-2024, 06:44 PM
  #1672  
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No doubt, like many 964 owners, I don’t often drive in the rain so windscreen wipers aren’t a focus. However with a 2,000 mile road trip coming up, it was time to look at mine.

I have standard size Hella wipers fitted. Their design looks like it was old in 1990, so I fell for the advertising of Wiper Tech.

They appear to have a more naturally curved stance and the blade wiper structure is different. Now I need some rain to see if they really are better.

Wiper Tech blade on the left vs Hella on the right

Hella blade structure.

Wiper Tech blade structure.

Old wipers

Wiper Tech blades fitted. They ran fine on a dry screen.
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Old 03-08-2024, 08:26 PM
  #1673  
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More road trip preparation. I removed the stock seats (24.5kg each) and fitted my bucket seat. A total weight saving of 35.6kg.

Fixed back bucket with manual fore/aft

Rails specifically designed for my height when I used to go to the track

The rails are recessed so the seat is down between the rails. Despite me being 6’4”, my helmet never touched the roof.
Old 03-08-2024, 10:24 PM
  #1674  
s65e90
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I'd move the wipers down a notch. Nice work, enjoy the road trip!
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Old 03-08-2024, 11:42 PM
  #1675  
John McM
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Originally Posted by s65e90
I'd move the wipers down a notch. Nice work, enjoy the road trip!
Good point, I’ll look at other RHD wipers to see where they rest.


13mm nut.

Nice to have the correct tools.

A bit lower. I’m not sure I can go completely flat.

Last edited by John McM; 03-09-2024 at 05:32 AM.
Old 03-09-2024, 06:25 AM
  #1676  
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Once again, you’ve has caused me to need another tool that I didn’t know existed- haha.

interesting that you chose the bucket seats for such a long trip! Must mean there’s gonna be some corners in your future. Who makes those seats again?

Why did you decide to take the 964 on this one? I’ve been itching for a spider ever since you first posted about yours but they’re just aren’t any around ( and I have to save up or let another car go.) having had both of them for a while now how do you feel they compare?

Pete.

Old 03-09-2024, 11:19 AM
  #1677  
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Nicely done.
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Old 03-09-2024, 02:15 PM
  #1678  
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Originally Posted by Peteinjp
Once again, you’ve has caused me to need another tool that I didn’t know existed- haha.

interesting that you chose the bucket seats for such a long trip! Must mean there’s gonna be some corners in your future. Who makes those seats again?

Why did you decide to take the 964 on this one? I’ve been itching for a spider ever since you first posted about yours but they’re just aren’t any around ( and I have to save up or let another car go.) having had both of them for a while now how do you feel they compare?

Pete.
The wiper puller is a luxury but it works so well. No damage to anything and the arm comes off so cleanly. No sudden uncontrolled release.

The seat is a Cobra RS seat. I think they are made in the UK. The base is narrow enough to allow the seat to go down between the rails. It’s so low, I need to fit gel memory foam cushions, and that doesn’t happen often at 6’ 4”.

So why this car and this seat?

The South Island of New Zealand has river valleys and mountains. Lots of curves on lightly traveled roads.

I took the 964 on the same road trip in 2014 and 2020.

Rennlister, Spokes, lives close to the Crown Range where this video was taken.

He has an ‘89 C4, a friend with GPW 964 and we’re letting a long hood owner come along as well.

We will hopefully be carving up corners at a good clip but not crazy speeds. My windows will be down and I hope to spend hours rowing the gearbox between 3rd and 4th. It is absolutely designed for the 964.

The Spyder would be epic on those roads, but not in keeping with the other cars.

Seats are very personal. My all time favourite seat was the 964 leather sports seats in my long gone Turbo 3.6. However, I had to recline the back to get a good seating position.

It is better with the standard C4 seats in this car, for some reason, but they are heavy and I still sit high in the car.

When I went to the track, my helmet would hit the roof so I had the Cobra RS fitted. It was brilliant and I got used to the fixed back. I also appreciated being able to relax in the seat and not have an aching leg from bracing sideways movement in corners. The Spyder has light weight buckets as well. I can understand why people baulk at fixed back seats. It just works for me and the weight reduction is noticeable. It also helps me get my shoulders at the perfect height for 2,000 miles of spirited driving.

Last edited by John McM; 03-10-2024 at 05:00 AM.
Old 03-10-2024, 01:28 AM
  #1679  
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I love the title of this thread . Just the documentation alone is probably more work than most light refurbs out there! I’ll appreciate all the tips and tricks when I finally embark on my two projects / thank you!
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Old 03-10-2024, 06:45 AM
  #1680  
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Yes I agree- this thread is gold with tis and tricks.

This roads are epic! The 964 was geared a bit high for my local roads (fixed that though).. still I'm jealous every time I see pics of your trips- places where the 964 can really stretch its legs. I just added some recaro sportster seats and I can just fit in a good position with a helmet. Really wanted a set of buckets but rear access is still needed. The stock seats are not light an easy to pull in and out are they? I have a set of the sport seats but they just didn't work for me with a helmet- or for my height.

Anyway- looking forward to some trip reports.
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