[flash]

these have now arrived at pete's and he is already installing them

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[Johannvb]

Hey Flash,

Is this brace compatible with the rear engine cover, and do I still need the strut brace in order to install this?

Thanks,
Johann

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[Fox944]

I have a rear engine cover i'm going to install, you need to cut a small triangle out of it for the brace. You also need the D1 Sturt Brace for the firewall, i swapped out my KLA Brace and installed both D1 Braces.

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[joeh944]

I'd like to install the firewall brace, but do not wish to install the strut tower brace. However, the firewall brace requires the driver's side strut tower bracket.

Would there be any interest in selling the driver's side strut tower bracket as a separate item? Thanks.

Joe

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[The_Oz]

<!--quoteo(post=67356:date=Feb 18 2009, 06:07 PM:name=968gene)-->QUOTE (968gene @ Feb 18 2009, 06:07 PM) <{POST_SNAPBACK}><!--quotec-->If you were a true Porsche purist you would design a special tool that would serve only one purpose (to install this brace) and then charge more for the tool than the brace. [img]style_emoticons/<#EMO_DIR#>/wink.gif[/img]<!--QuoteEnd--><!--QuoteEEnd-->

[img]style_emoticons/<#EMO_DIR#>/laugh.gif[/img] ... absolutely correct [img]style_emoticons/<#EMO_DIR#>/wink.gif[/img]

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[wmuldowney]

My brother in law is a Porsche mechanic and I like to rummage thru his bazillion dollar Snap-on tool box looking at the unique Porsche only tools and the custom, made by him, tools that serve one function for some obscure proceedure.

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[T-Bone]

I fully expected this installation to test the limits of my patience. However, it was surprisingly easy. Maybe because I lucked into having the right tools. It was suggested to me that the 2 halves be loosely joined together before installation. That way, you didn't have to thread anything in tight spaces. I lucked into having a shallow 1/2" short socket with the hex head (vs. starburst head) and a connected it to a swivel and log extension. It went together surprisingly without a hitch... until I realized that I had installed the connector bolts upside down (the nut on the top). The longest part of it was taking it all back off and switching the bolts around. Fairly straightforward job.

T-bone

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[Cloud9...68]

Ugh... I have a prospective buyer for my car, so I gladly agreed to a PPI, thinking there are no major issues with the car. To my shock, the PPI uncovered several very expensive problems, the biggest of which is, you guessed it, a cracked firewall. I haven't talked to the shop yet, as I just found out the PPI results tonight, but I'm wondering what are the chances the firewall brace could safely correct the problem. I've read through this entire thread, and it's not 100% clear to me whether the brace in purely intended as a preventative measure, or if it can correct broken firewalls. How could I find out? Thanks.

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[flash]

it won't fix it - it is more of a preventative measure



that being said, i have had plans to create one that would fix it - the design is done, but the demand had not been there, so i just hadn't gotten to it

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[Cloud9...68]

Well, put me down as customer #1. To put it bluntly, the results of the PPI on my car are devestating - I've done all the required maintenance, and then some, the car looks and runs great, and everyone who's driven it, including retired race drivers, have marveled at how well it drives, how smoothly it revs, how well balanced it is, etc. And yet, if I fixed everything that was found in yesterday's PPI, it would cost me close to eight grand. So, when I consider what I've spent on it to get it ready for sale, and the PPI issues, basically I own a beautiful classic Porsche with a net value of $0. Been spending the day trying to keep myself away from sharp objects, off of roofs, away from subway tracks (that one's easy - we don't have any in Austin), etc.



The firewall repair estimate alone is $2000, so having an alternative would at least help me dig out of the hole I find myself in, and fight off the temptation to leave the car in a disreputable part of town with the key in the ignition and the door unlocked. I'm also worried about why the firewall cracked, seeing as the car has never been in a corrosive climate. I'm concerned there's an issue with the clutch that triggered the problem, although it seems to work fine. Fixing whatever caused the firewall to crack wasn't even in the estimate. Sorry about all the doom and gloom; in the grand scheme of things, I'm sure there are worse things than seeing my dream of using the proceeds from the 968 go toward building a track car crumble before my eyes, but I'm having a little trouble seeing that at the moment...

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[banditsc]

Has the clutch pressure plate ever been replaced in it? You could have the heavier pressure plate that is sold these days.

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[flash]

wow - bummer - that's a bit high for that repair - let me see what i can do



this is the problem with these cars though - very basic stuff adds up in a hurry - essentially every rubber part in the car is due for a change - they aren't on any sort of maintenance schedule either - that can really add up



i'd be interested to hear what else they found though

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[Cloud9...68]

"Has the clutch pressure plate ever been replaced in it? You could have the heavier pressure plate that is sold these days."



Nope - its the original clutch, believe it or not, after 115,000 miles.



The mechanic who did the PPI explained to me that as the clutch pressure plate mechanism wears, its action changes in such a way as to require more pressure to disengage (I didn't understand the mechanism - I think I'd have to see one as he was explaining to to grasp the issue), and that, combined with an inherently poorly designed mounting for the master cylinder was responsible for the problem. He recommends replacing the clutch at 60,000 miles (!) regardless of whether it is giving any obvious symptoms, which mine really wasn't, even at 115K miles, although I'm sure the effect is so gradual it's difficult to notice.



He told me I might be able to get it repaired cheaper at a good body shop, but he really sounds like he knows what he's doing, and has done it many times, and after describing what he goes through to repair the firewall, I'm not sure $2000 is out of line. Based on my experience, I would recommend that everybody drop what they're doing and immediately order the D1 firewall brace. I know what you're all thinking, though - probably the same reaction I would have had to such a warning - "tough luck, but it'll never happen to me." Think again, and at least seriously consider it.



As far as what else was found, it's too far off topic for this thread, so I'll start a new one, although it will be the most depressing thread we've seen around here maybe since Lord Galva's accident...

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[flash]

the one "problem" with the Design 1 Racing firewall brace, whether it be the preventative one or the curative one, is that you will have to run a Design 1 Racing Strut Tower Brace - it will not work without it, as that is what it connects to

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[bombfactory]

Flash's firewall brace will also work with the KLA strut tower brace - you just have to shim where the brace attaches to the strut bar upright with a few washers and get a longer bolt.



I know Flash doesn't recommend using the firewall brace with the KLA unit, because the KLA upright does not have the extra triangulated brace that the D1R upright has, so do so at your own risk, etc.



Seems to be working fine on my car, however, my firewall still flexes - a PO installed a monstrously heavy HD clutch - but I feel a tiny bit better knowing the brace is helping a little.



-Austin

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[Carl968]

I have a KLA brace and I made a bracket that attaches to the upright and then to the shock tower. There is an existing hole in the shock tower which needed to be slightly enlarged and then everything bolted together. Seems to work without any consequences. What do you think?



Carl

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[968LS1]

Here is the firewall brace/bracket (11 gauge) I made to strengthen my firewall, the bracket also mounts the master cylinder. My car was originally a Titronic so the firewall was perfect with no stress but with the LS3 the larger clutch adds stress on the firewall so this is to prevent a possible problem in the future. Not shown in the photos are some tabs that bolts though he inner fender to eliminate any movement when the clutch is depressed. I feel sure you could fab up something similar for a lot less than 2K, it will require removal of the brake booster/master cylinder/brake lines and clutch master which is a bitch but is very doable. You will need to drill some more hole through the original firewall to bolt it on and that will require an angle drill. Sorry to hear you have this problem but you have a nice car and you can fix this issue for a reasonable cost.

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[flash]

that's serious!



wow - impressive - that's the kind of attention to detail you don't see most guys doing conversions even thinking about

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[Ryan]

LS...that is a work of art my friend. Very nice.

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[Cloud9...68]

LS,



Wow, that is impressive, but I'm afraid you vastly over-estimate my skill level. I couldn't craft something like that in a million years. But I am interested in any alternatives to spending 2K to have mine re-welded. Given the amount of work involved, $2K doesn't sound all that high, but again, I'm open to any alternatives. Who knows, buy the time I finish all the other items discovered in the PPI, Flash may have his firewall repair thingy ready...

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