Help, new door stay making loud popping sound

[jwakil]

I installed a new Porsche door stay on my 81, along with the reinforcement kit. I believe my install is correct, but the door is hard to go past the stops and makes super loud pop at each stop. At this rate I’m afraid even the reinforcement will get broken. Is this a problem with the stay itself or do I need to do something different? I read somewhere someone hade to grind down the bumps on the stay arm. Hopefully I don’t have to take it out as it was a pain to install.

[75 911s]

The pop is usually from the pin in the hole in the body side.

The arm is connected by a pin and the hole is worn out. The new part probably has stiffer springs in it so the pop is exacerbated now.

Some people take a 6mm bolt and replace the pin. You can then tighten it down and it kills the pop. They sell an aftermarket pin that is larger. It proved too big for my application and getting in there to ream it out is difficult access, so I stuck with my bolt fix for now.

[jwakil]

Originally Posted by 75 911s

The pop is usually from the pin in the hole in the body side.

The arm is connected by a pin and the hole is worn out. The new part probably has stiffer springs in it so the pop is exacerbated now.

Some people take a 6mm bolt and replace the pin. You can then tighten it down and it kills the pop. They sell an aftermarket pin that is larger. It proved too big for my application and getting in there to ream it out is difficult access, so I stuck with my bolt fix for now.

The bolt fixed the pop sound pretty well. But the door still feels too hard to open and close. I have lubed the stay arm pretty well, and hopefully it will gradually get better.

[75 911s]

Originally Posted by jwakil

The bolt fixed the pop sound pretty well. But the door still feels too hard to open and close. I have lubed the stay arm pretty well, and hopefully it will gradually get better.

What reproduction part did you buy? Not all parts are created equal. I've noticed a vast difference in aftermarket parts, some needing major modifications to get into spec.

The notched slider and wheels should have some sort of grease on them. Maybe white lithium, but I'm sure there will be other suggestions.

[jwakil]

Originally Posted by 75 911s

What reproduction part did you buy? Not all parts are created equal. I've noticed a vast difference in aftermarket parts, some needing major modifications to get into spec.

The notched slider and wheels should have some sort of grease on them. Maybe white lithium, but I'm sure there will be other suggestions.

I bought the more expensive Porsche brand unit from our host. I’m not pleased. I fear the extra force required will cause other damage. It’s not super hard, but it doesn’t feel right and I’m afraid after a few hundred openings something else will give.

[jwakil]

I ended up taking out the stay and grinding down the bumps on the arm and putting more grease inside the housing through the cracks. It’s definitely better now and doesn’t feel like something will break every time I open the door. I can’t believe Porsche sells this as is.

[917_Langheck]

The proper fix is in this thread:

https://forums.pelicanparts.com/porsche-911-technical-forum/172706-door-stay-repair-now-cant-close-door-2.html

About half way down page 2 (post #31)

[eastbay]

Originally Posted by 917_Langheck

The proper fix is in this thread:

https://forums.pelicanparts.com/porsche-911-technical-forum/172706-door-stay-repair-now-cant-close-door-2.html

About half way down page 2

BTDT on a bunch of doors and stays.

This is the proper fix, otherwise there is a good chance you will rip the guts out of the door

[Anjizkit]

I have the exact same issue on my drivers side door of the 87 targa. The passenger side is beautiful and silent.

Any pics of the bolt and pin you mentioned?

Thanks a ton in advance.

Originally Posted by 75 911s

The pop is usually from the pin in the hole in the body side.

The arm is connected by a pin and the hole is worn out. The new part probably has stiffer springs in it so the pop is exacerbated now.

Some people take a 6mm bolt and replace the pin. You can then tighten it down and it kills the pop. They sell an aftermarket pin that is larger. It proved too big for my application and getting in there to ream it out is difficult access, so I stuck with my bolt fix for now.