Well this is creepy.... I did the exact same thing this weekend and I concur that the issue is two fold; glue as well as the actual door card plastic frame is warping.

I removed the door cards and there are two issues, the glue separating as well as the breakaway corners broken.



In addition some material just disintegrating, had to brush it off else everything would get contaminated.




I used rubber and vinyl glue and applied with a brush all the way to the edge. I made a point to separate the foam trim from the plastic frame all the way front to back so that I would not have to go back in there when another spot fails and separates.
Then to make sure everything gets glued uniformly, I flipped it on its head. Making sure to stand it up on a hard and straight surface and to use a blanket!!!! don't want to scratch this POS




Didn't know how to fix the broken plastic around the security LED. its a breakaway point for a reason. Superglue wont work so I decided to use hot glue gun. It holds strong enough but can easily detach.





At first results looked promising, I was happy.




But unfortunately after the car warmed up….





I can feel it from the inside and the glue didn't separate, its the freaking plastic frame of the door card that is getting deformed.

Next weekend I'm going to see if I can perhaps alleviate some of the pressure from plastic when it expands by freeing up the screw a little at the mounting point on the end of the door.

If anyone has anything additional they tried, please feel free to share. And getting new door cards for 4 grand is not the answer......

 

Heat the marked area with the heat gun and apply pressure on top side to return to original form.

 

When the car cools down its fine, when weather gets ~75 warping occurs. Not sure if what you are suggesting will help as it will warp again as soon as in the sun. But I will try in couple weeks.

 

After reading another thread on a minor accident a user had on his 991 6 days after taking delivery that was just mainly cosmetic, I was curious and looked up a 2017 991.2 that I saw in Dallas that had an accident. Reviewing the Carfax the accident seemed minor, like a parking lot accident. But i saw another interesting fact. The 2017 also had the door panel fixed. Must not only be an issue on the 991.1.

 

I guess that's not surprising as, as far as I know, Porsche has yet to fix this (probably never will at this point) and the 991.2 uses the same door panel.

 

I just had mine replaced (2014 991.1) last week under CPO warranty - both sides. While it was a no charge fix, I was a bit surprised to see that the materials seemed to be exactly as the original, it wasn't evident to me that they have not changed the parts used. I expect the replacements to probably separate some time in the future as well.

 

I had mine replaced as well and the service manager said the new ones are the exact same and shared part number. Amazing they would replace with the same thing and expect one day to fail. I have been applying 303 juice to protect but really am just hoping by the time they fail again the aftermarket will come up with a correct fix.

 

When mine were replaced, the dealer told me that the would replace 'em again if (when) the new ones fail.

 

Mine just got replaced too (well one of them) under CPO warranty. They had to order the other side. As a side note, I was also able to take care of the windshield goop issue too.

 

Interesting development - looks like some folks are trying to pull together a class action around this issue:

https://www.facebook.com/groups/2358...851/?ref=share

 

I have joined the group.

 

Grrrrrr... I just purchased a second hand fully loaded 2014 Porsche Boxster S and the car was not selling because of the separation on the door panels was such that one could stick the palm of the hand down with ease and it was in a Jaguar dealer. Not being a Porsche dealer they tried the cheapest trick possible. They glued them with the strongest epoxy they found. Yet the foam panels wouldn’t stay down. I was able to negotiated down quite a bit because I assumed the cost to fix this was $5K+ plus the hazle. I never have been able to knock down so much out of a car and have them being ok with it.

To shorten the story... I don’t have a warranty or bought it as a CPO because it wasn’t an option. So I have drilled a few small holes and stitched the plastic panels with metal wire making sure it wouldn’t compromise the deployment of the air bags (or so I think). Now, I am trying to glue the foam with JB weld for plastic bonds and car body panels... in case that bonding doesn’t hold I bought industrial strength velcro and T-Rex mounting tape also for door panels and somehow will try to use both.... lets see what happens tomorrow.

 

Good luck. Hope one of your solutions work.

 

I'm looking to buy a 2014 C2S that is just about perfect, except the driver's side panel is already separating... Seller said this is an 'easy, quick fix' but over the weekend I looked around the forum and other places, and the solution does not at all seem as 'cut and dry' as he claims to be, which is irritating. How much realistically can I negotiate down on something like this?

 

Look up the price to buy and install a new door panel and deduct that amount from your offering price. If you are good at DIY that panel does come off quite easily.