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I can’t believe Porsche never addressed this over the entire 34 year run of air cooled 911s! I had a longhood and an SC years ago and this was a well known problem for those cars too. Porsche must have been aware of the failures for at least a couple decades before the end of 993 production.
I understand that the hi/fi sound system 993 doors are about 20 kilos heavier than the initial 911 doors. It may be that the hi-fi builds had the reinforcement because of the added door weight. Just speculation on the last part but easily confirmed with a poll of build date and factory-type welds y/n and whether the car came with hi-fi soond.
20 kilos is 45 pounds. The hifi speaker pod that's under the door pocket weighs a few pounds. It's plastic and has two small speakers mounted on it. Non-hifi has one larger speaker. I'd guess the difference between the two is a couple of pounds. Plus the speakers are close to the door hinge, so there's little polar moment. I am quite dubious of this theory.
Looks well done, who did you wind up using for the repair?
rob
Thanks. I pulled the door and sent it to a friend who does lots of welding and fabrication. I bought custom mixed rattle cans to paint it, then re-hung the door.
I really wanted someone who had done the job before to tackle it, but the work my friend does is top notch, and when he agreed to do this even though it's a bit outside his wheelhouse I jumped at the chance.