Removing rocker covers?

[RickKlem]

I'm installing an external oil cooler on 77 911 and the car has never had a set of oil lines that run up the side of the car installed.
To install the oil lines, do I have to remove the rocker panels and if so how do I remove them?

Thanks
Rick

[kstylianos]

Rick,

I don't know if you NEED to, but it will make it much easier. Takes about 10 minutes to remove the rocker cover.

There are 2 cover plates at each side (fore & aft) of the rocker cover that need to be removed....2 phillips sheet metal screws per cover.

This will allow the rubber protection strip to be peeled off the rocker cover. Just grab one end and peel like a bananna. Use soapy water in the guides when you reinstall. You'll need to slide it back in.

The rocker cover is also attached with phillips sheet metal screws (4-5 I think) in recessed holes that are covered by the rubber protection strip.

All done.....

[RickKlem]

Thats it?

Great !!!

Thanks
Rick

[banjomike]

There is actually a bit more to it.

Along the bottom there are three other screws. They each screw into a welded on bit that I call the standoff.


The brackets (part 21) that hold the oils lines in place under the rocker screw into these same bits.


When you take off the rocker (which is absolutely required) the three bolts along the bottom will have a washer, then the tabs from the rocker panel then a spacer and then they go into the the standoff bits. The oil line brackets will take the place of the spacers.
One oil line runs above these standoffs and the other runs below. I found that the existing srews weren't quite long enough. So I bought some longer bolts with the same diameter and thread pitch and then ground them down to a bit over 1" each. They must be long enough that they reach through all of the pieces they hold together and reach the hole in the standoff. But they must be short enough that when you have tightened it down completely they arent digging into the body.
I installed, removed, tightened, loosened, many times as I bent and adjusted the lines so they would all fit into all their connections. Once I had all of the hardware in place and it seemed to fit right, I loosened the three bolts and then tried slipping the rocker panel tabs under the washer on each bolt. This step would have gone more smoothly with some help. At one point it was on one bolt and slipped and the whole rocker panel pivoted and I thought for sure it had scraped up the door or fender paint. Anyway wiggle it on until the holes for the 5 sheetmetal screws line up, snug it all down, and presto! Getting the rubber back on was pretty easy once I got the hang of it. Some soapy water and a narrow head standard screwdriver to push the lower flap into the groove and there you are.

At first I thought I was doing it all wrong. with the rubber spacers around the lines I never thought it would fit right, but it is just very tight.

Of course I'm not really done. The new lines rub my rear tire under hard cornering. BTW none of these screws just go into the sheetmetal. There is always a hole of the right size there for you, and each of these holes comes equipped with a nut welded onto the back side for strength.

Good luck!

[RickKlem]

Mike ,

Thanks for the info. I was thinking about using sheet metal screws. But since I have read your post I have decided to find the three clamp (21) pieces and mount it the correct way.

Thanks

Rick