Front suspension pan replacement tips?

djb25 · 08-02-2007, 01:14 PM

Hi everyone,

I had a little shock the other day when I looked under the front of my '77 911S - I discovered that the driver's side a-arm mount had pushed into the suspension pan!

The car had corrosion in the battery-mount area since I purchased it in 2000, but I had been informed that a "patch" had been performed in that area (in fact, the shop that did the patch-work told me about it).

A little further investigation revealed that the patch was exceptionally poor work, and was (for some reason) covered in silicone.

Anyway, I'm looking to replace the pan now... I've read a lot of the posts on this topic already. However, if there is anyone out there with a few pointers or tips, I would appreciate it.

Lastly, I'm going to throw a few pictures up tonight, and maybe someone can tell me if I am going to need to replace the tank support as well as the suspension pan. The corrosion seems to be fairly contained within the area of the front a-arm mount, but I may just be hoping...

sballard · 08-03-2007, 05:04 AM

Damion-

Welcome to the world of rusty pans. Many posts on this in the archives and a few recently including my own. Do a search and be sure to check out the older posts. I can assure you that the tank support will have to be replaced and possibly the longitudinals. I and many others have gone through this. I am nearing the end and have learned alot. It was a lot more work than I thought but quite doable. I would not take it on unless I had a garage or at least a good shelter. I've been very deliberate, working evenings and my car's been up on stands for about 2 months. But it's actually been kinda fun in a perverted way and allowed me to have some serious bonding time with my car!

djb25 · 08-03-2007, 07:15 AM

Steve,

Thanks for the words of encouragement!

I have access to a large garage and a large assortment of tools, so that part of the project should be covered. Fortunately, I also have access to some people capable of welding, just in case I screw up terribly.

And yes, the list archives have a wealth of information on this project, if it wasn't for the archives, I probably wouldn't have felt comfortable taking this on.

- Damion

911K · 911K's Garage

Ed Mayo has an excellent write-up on his site with photos that documents the whole procedure.

http://webpages.charter.net/mayo/Pan_files/v3_document.htm

berettafan · 08-03-2007, 09:32 AM

welding should be, IMO, the easy part. so far i've just removed stuff in my pan replacement quest but i can tell i now look forward to the welding part and expect it to be a nice relief from grinding.

djb25 · 08-03-2007, 11:38 AM

Quote:

Originally Posted by 911K

Ed Mayo has an excellent write-up on his site with photos that documents the whole procedure.

http://webpages.charter.net/mayo/Pan_files/v3_document.htm

Nice link!

Curve Eater · 08-03-2007, 12:28 PM

I had the same issue a couple of months ago. When we pulled the existing pan, the rust had gone back to the aft section of the trunk. Definitely get new tank supports, and plan on doing some patch work with lightweight aluminum that will cover what the new pan does not.

The welding was straightforward, but took a while. Make sure that you get the correct fitment for the gas tank, as you will have trouble opening the gas fill nozzle (ask me how I know).

Many of the pans available are from less developed countries, and the fitment is terrible. I will say that if you need a new pan, do NOT get it from Restoration Design unless you can find no other option. The fit and finish is excellent, but it took 2 months to get it. When I called the shop next door to them, they told me that they get a lot of calls to see if the guy is still in business. I had the local polizei go by there, and they told me that they get complaints all the time. The guys voice mail is filled all the time.

Bill

sballard · 08-03-2007, 01:32 PM

My longitudinal supports were only rusted at the most extreme front end and I was able to fabricate repairs from sheetmetal stock The price of the longitudinals is steep. I would suggest waiting to see if you need these parts until you get the tank support off and evaluate what's rusted beyond repair. Also, you will need to buy support backing plates for the A-arm mounts on the new pan (I can't remember the formal name just now).

I was lucky and got my pan from RD about 2 years ago, but I haven't been able to get any response from them since. Too bad.

djb25 · 08-03-2007, 01:59 PM

Great. I had been under the impression that restoration design had got their act together and was reliable again... and as such I ordered the suspension pan and tank support from them last night!

Maybe I'll get lucky and my order will slide through... ha!

- Damion

berettafan · 08-03-2007, 02:34 PM

tried RD and gave up after 4 months. Stoddard has been very reliable.

djb25 · 08-09-2007, 10:22 AM

Well, I ordered a new suspension pan and gas tank support from rennsport in California (off of ebay, incidentally) and the parts are already here! I think I placed the order sunday night, and they showed up here (in PA) at noon today!

They look like decent parts, but I have nothing to really compare them with (first time doing something like this) but I can say that their service is fantastic. They also included the reinforcing clamp things that go over the a-arm mounts, which I hadn't anticipated - a very nice surprise.

Much nicer response than restoration design - whom I placed an order with two weeks ago, and have yet to hear ANYTHING from - even after leaving three messages! So, I may end up with a set from restoration design as well, so if someone needs the parts this time next year, let me know! I MAY have them...

Now the fun begins... although it doesn't look like its going to be THAT bad.

- Damion

berettafan · 08-09-2007, 10:29 AM

i just got a call from Bill at RD. my stuff is in stock and shipping. looking forward to it. btw if anybody cares he is much cheaper on the tow hook than Stoddard.