I have a 97 993tt with 60K miles. The door strap was making a clicking noise and I could see the strap moving back and forth by 1/8". I read all the posts on this and other web-sites regarding this apparently common problem. The repairs I found called for either (1) welding the bracket that the strap attaches to to the sheetmetal opening or (2) cutting open that panel, re-welding the base of the bracket and welding a patch over the hole into the panel. I chose a much less drastic method that I'll detail here. Hopefully, it will stand the test of time and usage.

The first thing I did was to replace the old strap. It’s easy to do and I believe the cost of the part was around $30. As part of that process you have to remove the pin that stakes the strap into its bracket. Before reinstalling the pin I took a 3/4" plastic pipe fitting and cut out a piece to make a wedge to fit the space between the bracket and the sheetmetal. I cut the plumbing pipe with wire cutting pliers and filed the edges to make a tight fit. I pressed the newly created plastic wedge into place using a drift and light taps with a hammer. The door now closes much quieter. There is still a little flex in the bracket but no more than a few 100ths of an inch. I've attached a few pictures.
https://rennlist.com/forums/attachme...1&d=1326765927
Bracket with the plastic piece inserted.
https://rennlist.com/forums/attachme...1&d=1326765927
Hammer and drift to tap plastic in place. Needle nose pliers not used.
Tape to protect paint when tapping in hinge pin.

 

DIY for your first post? You're the man!

Now post pics of your turbo!!!

 

I've got the clicking noise. I'll try this.

 

I have never heard of this happening with any other make of car. My dad bent the door right back on his little POS Ford in an unfortunate accicent but the strap bracket didn't snap the welds so why is it such a common failure on the 993?

Was it a problem with previous 911's or was there a design or production problem in our 993's?

 

From what I found while researching this problem on the internet, Porsche decided to save some $$ by omitting one spot weld securing that bracket. Prior models had 3 spot welds, 993s had only 2. This maybe wrong but it sounds logical and I have no way to inspect that area of our cars. BTW my passenger door bracket is rock solid - maybe because it rarely gets opened. Regarding pictures of my car - I can't find them. Also I'm near Chicago and it is taking a nap in a nice heated warehouse.

 

the weld on mine is bad - passengers side - need to take apart and see what to do.. probably a weld job. Added to the project list!

phil.

 

Not letting the door swing open until it gets stopped by the strap is a good preventative measure.