SC window switch repair goes smokey

[Robey5]

SO:

I decided that I would take a shot at aligning my windows on the targa, so that I could at least eliminate a little bit of the wind noise at speed that is not created by the rest of the mess (thank you for the posts, Dan of Carsinc). Along for the ride, I figured that I would try to get the window switch wiring connections more secure; because the various POs were a little sloppy about using shrink tubing where it needed to be replaced over the years.

What I did not realize was that I had a bit more of a science project to tackle (that I am glad that I caught NOW.

The power (window) wires that go into the door from near the A-pillar were getting pinched at the hard stop (more on that later) and I put together my "completed" project ready for a test. I connected the battery, turned the key, and saw smoke pumping out of the A-pillar door jamb, near the hinges - meaning that bad things happened. After I nearly injured myself running to disconnect the battery and grab one of the 4 fire extinguishers in the garage, I knew that I had a bit more of a project to tackle than previously forecast. Once the smoke cleared (literally) ... and after fighting with the wiring, I was able to pull it back through the butt side of the door, I realized that I uncovered a mess that has been brewing for a while. Enjoy the pictures; thankfully I did not have a car-b-q to bring in the new year....






Anyhow, I did a cursory search in the parts section of the host's catalog --- What is the black part that (I believe) goes on the end of the door stop?

[Robey5]

I looked in the "PET" and it does not show that black part that (I believe) goes on the door stop. Does anyone know what this part is? I would hope that the host has one....

[pmax]

It's probably part of the harness.

[Robey5]

The center of this plastic part has a square cut out, I am pretty sure that it was supposed to be connected to the end of the door stop. Perhaps it is a little piece of foam, or a soft-stop on the mechanical door stop.

I will take another picture of it when Im back in the garage... I think that the wire harness (when I look in the PET) is just 4 wires, a covering, a seal for the door-pass-through and the round 4 pin connector on the A-pillar.

[911obgyn]

I had the same situation on a 1985 only a lot more wires, mirror, window, speaker. All had been wearing over the years. I ended up replacing and reinforcing the door stop and while I had the door off I unplugged the harness near the A pillar in the trunk and repaired the harness where it flexed in the door, sorry no pictures.

[Robey5]

Yeah; I too have the speaker wires, as well as the power mirror wires, so there's no doubt it is a mess of "hot" wires going in there that were wore down to nothing...

I decided to just replace that wireharness: man, you want to talk about a porsche tax....

I decided that it would be a better move than soldering in wire to be a cheap-ace, and then have potential problems down the road (did I mention that I am not a fan of removing the door panel?). Also, this way: I can sure up some other things inside the door that have been lingering. I suppose this way: I've paid the tax to ensure things are not going to burn to the ground when I attempt to roll the windows back up on some unsuspecting summer drive. ... at least not from THIS circuit.

The little block that is broken: here's another picture. I got into the passenger door and confirmed that this is a little foam/plastic block that goes on the end of the door stop, perhaps to soften the blow of a "hard" stop against the full opening position.


It's not in PET. Anyone out there know what htis thing is called so that I can attempt to buy one? Or, am I off to the shop to try to make one?

[pmax]

Originally Posted by Robey5

Yeah; I too have the speaker wires, as well as the power mirror wires, so there's no doubt it is a mess of "hot" wires going in there that were wore down to nothing...

I decided to just replace that wireharness: man, you want to talk about a porsche tax....

Why would the wiring wear out to nothing in that relatively benign location, heatwise, unless there have been previous shorting incidents ? If it's somehow age related, I would worry about the wiring throughout the car, probably not the only place where it has worn down.

[Robey5]

"Why would the wiring wear out to nothing in that relatively benign location, heatwise, unless there have been previous shorting incidents ? If it's somehow age related, I would worry about the wiring throughout the car, probably not the only place where it has worn down."

My statement about wiring was kind of a joke on my end. In this instance, the wires were getting pinched against the hard stop for years without my knowledge, and finally we had an incident. As I am going through this car in bite sized chunks over the years, I am noticing that there are other areas that COULD have been left like this for years.

[Robey5]

Does anyone know what this door stop thing is?