DIY screw up ....
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Three Wheelin'
Joined: Mar 2002
Posts: 1,548
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From: Belgium
DIY screw up ....
As proposed on Mike J thread, I'd like to start a thread where we could confess what we screwed up or forgot during our DIY.
Those details that when forgotten can cause you problems during days or month, details that can cost you money or stress before you finally find the cause and cure it.
I will start with mine:
When I performed my first engine drop, everything ran well... But at every bump ma car was feeling on the road, a weird "clonk" sounded somewhere in the back. I checked all the engine mounts, bolts etc... Nothing wrong until after a few weeks I finally found that I forgot to lock a bolt which holds the gearbox support to the body!
one of the six yellow arrows!
Go ahead MikeJ, yours is even nicer!
Those details that when forgotten can cause you problems during days or month, details that can cost you money or stress before you finally find the cause and cure it.
I will start with mine:
When I performed my first engine drop, everything ran well... But at every bump ma car was feeling on the road, a weird "clonk" sounded somewhere in the back. I checked all the engine mounts, bolts etc... Nothing wrong until after a few weeks I finally found that I forgot to lock a bolt which holds the gearbox support to the body!
one of the six yellow arrows!
Go ahead MikeJ, yours is even nicer!
Last edited by Toga; Aug 18, 2006 at 05:49 PM.
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Joined: Jun 2005
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From: Neither Here Nor There
I'll throw one in:
During my suspension install that resulted in the DIY instructions in my signature, I was reinstalling my upper spring perch on the front right corner of the car. I'm not sure if it was my screw up or metal fatigue, but when I was tighting one of the 13mm nuts (even before torqueing), I sheared one of the threaded studs right off. Unfortunately, those threaded studs are integrally formed with the upper spring perch, thus requiring a brand new perch....... $135'ish. Ouch.
Thus leading to the following warning in the DIY instructions:
During my suspension install that resulted in the DIY instructions in my signature, I was reinstalling my upper spring perch on the front right corner of the car. I'm not sure if it was my screw up or metal fatigue, but when I was tighting one of the 13mm nuts (even before torqueing), I sheared one of the threaded studs right off. Unfortunately, those threaded studs are integrally formed with the upper spring perch, thus requiring a brand new perch....... $135'ish. Ouch.
Thus leading to the following warning in the DIY instructions:
(F35.) Tighten each of the four (4) 13mm nuts at the top of the shock tower to a torque setting of 18-24 ft/lbs using the 13mm socket, 3/8” extension, and 3/8” torque wrench.
TIP: The proper Porsche spec for the torque of these four (4) 13mm nuts is 24 ft/lbs. However, there have been cases of the stud shearing off under 24 ft/lbs, possibly due to metal fatigue. If this happens, you will need to replace the entire spring perch. (Ask me how I know.)
TIP: The proper Porsche spec for the torque of these four (4) 13mm nuts is 24 ft/lbs. However, there have been cases of the stud shearing off under 24 ft/lbs, possibly due to metal fatigue. If this happens, you will need to replace the entire spring perch. (Ask me how I know.)
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From: Wrightwood, CA
Years ago I put in too much oil - make that WAY TOO much oil - in my '86 Carrera. Naturally, I made the rookie mistake of checking the oil when the engine was cold. I didn't even realize I had made an error until I noticed that I had just killed half of the mosquito population in California (all that white smoke coming from the engine!)!
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From: Shrewsbury MA
When I did my suspension install, I did not secure one of the blue dust boots to the top of the Bilstien HD strut. After my install, I rode around with a squeak that was generated when the dust boot rode up the strut as I drove over a bump in the rode. It took weeks to find the source of the squeak. I first thought it was the new swaybar bushings. I oiled, siliconed, greased those damn bushings. I finally pulled both swaybars and completely greased each bushing, front and rear. no luck. I was about to pull the strut itself when I happened to hit the dust boot and heard the squeak. So simple, felt like a dope.
Race Car
Joined: Sep 2004
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From: Wilmington NC
When I bought my car, it was virtually sight unseen until the day I picked it up for the 1000 mile drive home. It seemed kinda slow........when I got it home I opened the back decklid to find that there was no Turbo 
I knew the price seemed cheap! But it looks like a Turbo......guess thats what I get for buying a 4S
I knew the price seemed cheap! But it looks like a Turbo......guess thats what I get for buying a 4S
Instructor
Joined: Jul 2006
Posts: 139
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From: Northern Virginia
Originally Posted by 993inNC
When I bought my car, it was virtually sight unseen until the day I picked it up for the 1000 mile drive home. It seemed kinda slow........when I got it home I opened the back decklid to find that there was no Turbo
I knew the price seemed cheap! But it looks like a Turbo......guess thats what I get for buying a 4S
I knew the price seemed cheap! But it looks like a Turbo......guess thats what I get for buying a 4S
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From: Vancouver, BC
Optima Battery Installation
OK, I have a new one.
I was installing an Optima battery in the car before the Portland Parade a few weeks ago since the lead acid one was toast. You have to bend the positive terminal because the posts are farther in on the Optima. I had the battery in, positive just about right and negative not connected. I was bending the positive just a little bit more with a set of vice grips and my hand slipped......
and my Engineer's ring on my pinky touched the negative WHILE I was holding the wrench. 600 Amps discharged through the ring and it turned red hot. Holy Crap!! I ran out of the shop up the stairs to the house and the door was locked!! I fumbled fo the keys as the ring continued to burn into my finger...I then got in and put the finger/ring under cold water. Now what? Loks bad!! So I did a DIY ring removal...I first checked that the finger was still strong enough for the twisting and then started to reef on the ring (which had not been off for more than 20 years). I managed to get it off by rotating the ring on the burn and then twisting it off with soap....
The doctor told me that it was a smart move which likely saved my pinkey. Its pretty bad burn right though the skin into the meat all away around the finger. I have been changing dressings for the last three weeks, no swimming this summer, and taking showers with your hand in the air is a pain in the a**.
So what did I learn from this "DIY"?
1 - Wear mechanics gloves when installing batteries.
2 - No rings (even though I have done 20+ years of fooling with cars with my engineer's ring)
3 - Flamizine ointment is your friend.
3 - Damn batteries can sure kick!
Cheers,
Mike
I was installing an Optima battery in the car before the Portland Parade a few weeks ago since the lead acid one was toast. You have to bend the positive terminal because the posts are farther in on the Optima. I had the battery in, positive just about right and negative not connected. I was bending the positive just a little bit more with a set of vice grips and my hand slipped......
and my Engineer's ring on my pinky touched the negative WHILE I was holding the wrench. 600 Amps discharged through the ring and it turned red hot. Holy Crap!! I ran out of the shop up the stairs to the house and the door was locked!! I fumbled fo the keys as the ring continued to burn into my finger...I then got in and put the finger/ring under cold water. Now what? Loks bad!! So I did a DIY ring removal...I first checked that the finger was still strong enough for the twisting and then started to reef on the ring (which had not been off for more than 20 years). I managed to get it off by rotating the ring on the burn and then twisting it off with soap....
The doctor told me that it was a smart move which likely saved my pinkey. Its pretty bad burn right though the skin into the meat all away around the finger. I have been changing dressings for the last three weeks, no swimming this summer, and taking showers with your hand in the air is a pain in the a**.
So what did I learn from this "DIY"?
1 - Wear mechanics gloves when installing batteries.
2 - No rings (even though I have done 20+ years of fooling with cars with my engineer's ring)
3 - Flamizine ointment is your friend.
3 - Damn batteries can sure kick!
Cheers,
Mike
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From: Los Angeles
My recent screw up was much less dramatic. I recently did the oil cooler ballast change. I was very happy with myself after getting through everything, following the p-car instructions as best as possible and saving me some money in the process when I dropped my drivers side foglight. They crack when you do that!
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Three Wheelin'
Joined: Aug 2005
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From: Long Island, NY
Not so much a DIY screw up ...but some things that that y'all should look out for!
When you are waxing/polishing your car:
-- take off your wristwatch and, yes, if you have a humungo ring -- that too!
-- do not wear pants that require a belt or sport any form of 'big' belt buckle
-- do not wear jeans/dungarees that use 'copper studs'
-- have a 'clean' t-shirt and 'clean' pair of shorts and a 'clean' pair of sneakers on 'standby'. Why? Because after you have completely skanked up the set of clothes that you have been wearing all day (cleaning the car) -- if, at the end of the day, you 'forget' and then get in the car to put it back in the garage -- you have just 'ruined' your seats/vinyl and, yes, steering wheel too.
G.
When you are waxing/polishing your car:
-- take off your wristwatch and, yes, if you have a humungo ring -- that too!
-- do not wear pants that require a belt or sport any form of 'big' belt buckle
-- do not wear jeans/dungarees that use 'copper studs'
-- have a 'clean' t-shirt and 'clean' pair of shorts and a 'clean' pair of sneakers on 'standby'. Why? Because after you have completely skanked up the set of clothes that you have been wearing all day (cleaning the car) -- if, at the end of the day, you 'forget' and then get in the car to put it back in the garage -- you have just 'ruined' your seats/vinyl and, yes, steering wheel too.
G.
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Joined: Aug 2005
Posts: 10,694
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From: I should be in TNT for Carnival!
I hadn't done this but probably might have.....think about it every time I jack the car up....
https://rennlist.com/forums/993-forum/276761-don-t-do-a-bonehead-maneuver-like-i-did.html
RIP Ray.....
https://rennlist.com/forums/993-forum/276761-don-t-do-a-bonehead-maneuver-like-i-did.html
RIP Ray.....
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Joined: Nov 2004
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From: Fort Collins, Colorado
When changing the oil for the second time I thought I remembered the instructions well enough to not need to read them again. (Plus they were home and I was at my shop.) I changed the oil and filters, seemingly without incident. Started up the car and the oil pressure was way too low. My mistake: Draining out the oil from the pressure relief valve on the bottom of the engine instead of the drain plug on the side, then not noticing the springs and pistons sitting in the bottom of the drain pan. 
Pro
Joined: Feb 2006
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From: Riverside, CA
When I first got my car I changed out the pollen filters at the same time as the spark plugs. I noticed that after that the vents in my car would shut down whenever I turned on the AC or when I had on recirculation. From searching the database here, I was convinced that a vacuum line in the engine compartment had become dislodged when changing the spark plugs. I spent too much time looking around back there but never found anything wrong. Months passed. As I reviewed in my mind the work I had done, I decided to check up front by the pollen filters. I found a small black vacuum line had been dislodged in the front of the car by the pollen filters. AC/recirculation function was restored.
Pro
Joined: Feb 2002
Posts: 613
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From: New Jersey
I'm not sure I want to admit this, but I think I have one of the costliest DIY FUBARS:
A coupe of years ago there was a GB on RS motor mounts. The DIY looked simple compared to other work I've done in the past (suspension, brakes, etc.) Anyway, I get the first mount replaced with no problem and then proceed to replace the second.
I get both of them in and get out my torque wrench to tighten them down to spec. I adjust the wrench properly and begin to go at it. The wrench keeps turning and turning and it never clicks. Needless to say, I snapped the bolt in the body of the car (there was something wrong with the wrench).
However, I then decided to try and drill out the broken bolt from the body and ended up breaking/jamming a diamond blade bit in the hole with the broken bolt. I tried for hours to get it out but didn't have any luck.
So I call up my Porsche independent shop and make an appointment to drive it there for them to fix it.
According to my mechanic, it took them almost 14 hours to get it out because the diamond blade bit would not budge. They tried a number of times to weld a nut to the exposed bolt and that snapped off without the bolt budging. They eventual had to make a "jig" and slowly drill out (from small bit to large bit) the entire mess without damaging the original threads on the part that's welded to the car.
That cost me $1200 and is probably the most expensive motor mount install ever on a 993!
A coupe of years ago there was a GB on RS motor mounts. The DIY looked simple compared to other work I've done in the past (suspension, brakes, etc.) Anyway, I get the first mount replaced with no problem and then proceed to replace the second.
I get both of them in and get out my torque wrench to tighten them down to spec. I adjust the wrench properly and begin to go at it. The wrench keeps turning and turning and it never clicks. Needless to say, I snapped the bolt in the body of the car (there was something wrong with the wrench).
However, I then decided to try and drill out the broken bolt from the body and ended up breaking/jamming a diamond blade bit in the hole with the broken bolt. I tried for hours to get it out but didn't have any luck.
So I call up my Porsche independent shop and make an appointment to drive it there for them to fix it.
According to my mechanic, it took them almost 14 hours to get it out because the diamond blade bit would not budge. They tried a number of times to weld a nut to the exposed bolt and that snapped off without the bolt budging. They eventual had to make a "jig" and slowly drill out (from small bit to large bit) the entire mess without damaging the original threads on the part that's welded to the car.
That cost me $1200 and is probably the most expensive motor mount install ever on a 993!
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From: Sandy, UT/Fish Haven, ID
I have NEVER had a screw up with a DIY. Im batting .1000 with changing a bulb in the tail light.
On the other hand, I have had a shop scew up a few things after doing work on my car-like forgetting to screw back down my CD changer in the hood and oil run off from an oil change. Nothing like having your oil changed, come home, load the car up and getting ready to head to Tellurdide and you notice a big oil spot in the driveway. I dont know how many people let oil drain on the engine tray but that was first for me. I no longer use that shop and they did thousands of $$$ in work but the got sloppy on the little things. Nothing better than paying a bill for $5k in upgrades, then your stereo starts acting up and look in the trunk to find the CD changer is no longer screwed back on and bouncing all the place.
On the other hand, I have had a shop scew up a few things after doing work on my car-like forgetting to screw back down my CD changer in the hood and oil run off from an oil change. Nothing like having your oil changed, come home, load the car up and getting ready to head to Tellurdide and you notice a big oil spot in the driveway. I dont know how many people let oil drain on the engine tray but that was first for me. I no longer use that shop and they did thousands of $$$ in work but the got sloppy on the little things. Nothing better than paying a bill for $5k in upgrades, then your stereo starts acting up and look in the trunk to find the CD changer is no longer screwed back on and bouncing all the place.
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From: YQU
During my first oil change I cross threaded the oil filter and the engine puked 1/2 the brand new oil I had just put in on my garage floor as soon as I started it up. 
Marc
Marc