Door Fitment and Operation Woes and Repairs

carwash · 12-17-2016, 06:04 AM

So, since I got this car, there has always been a passenger door issue, or rather issues. 1968 912 chassis, for reference.

There was always a gap and fitment issue. First off it has fiberglass front flares, and they never line up perfectly, at least not that I have seen, without 90 hours of glass work, etc. I can deal with the gaps up front, but it had an uneven gap at the top where it closes, you know, the spot where you look every time you grab for the handle, and stare at its unevenness. I can't stand that. So i thought easy enough, get some shims for the hinges.

Ordered up shims from Pelican and went to work. Supported the door with a 2x4 and a floor jack. Dug out the 50 years and layers of paint out of the 12-point bolts that hold the chassis portion of the hinge onto the jam. Snuck a shim in behind it and put the bolts back in. (don't lose these bolts by the way, they are no longer available to purchase, and they are an odd bird with a shank and large shoulder etc).

Door was still a little low at the handle. So I started over and out two shims in, and that was WAY too much, it sat way high. Removed the one shim. I need a half shim, lol. So instead I adjusted the striker plate in the door up a smidgen to make up the rest of the gap, works perfectly and lines up, and closes nice and solid. pics!

carwash · 12-17-2016, 06:16 AM

Now my other issue was the outside opening of the door. It didn't work well. With button fully depressed, I had to pull with all my might to get it open. I had assumed the entire time that it was fitment causing a bind etc. But no. Now that the door is lined up properly, it still has issues opening from the outside. So i figure it has to be the handle mechanism or something inside. By the way, the door opens fine from the inside using the release.

Rolled the window up and put a light in there (door panels are off for full build so this was easy). I found that when depressing the button on the outside handle, the cylinder would push the lever just so far, but then it would move the entire assembly, not actuating what needed to be pushed. This took me to find the points of mounting of this assembly, which are on the outside jam of the door. And here I found my issue. On the passenger side one screw was missing and the other is broken. On the driver side, same issue. So now when I disassemble these doors for paint, I will have to do some drilling and extracting on these parts. Does anyone know what screws these are and if they are still available? Pics!

carwash · 12-18-2016, 07:19 PM

Does anyone know what screws these are and if they are still available?

Cairo94507 · Cairo94507's Garage

You might try European Auto Salvage Yard (EASY) in Emeryville, CA or Parts Heaven in Hayward. They may have the bolts you need. Good luck.

carwash · 12-19-2016, 05:09 AM

Thanks!

Fast Freddy 944 · Fast Freddy 944's Garage

Man o man bubba, you ever hear of nail clippers! LOL

You might check your frame for tweeks, if doors and quarter panels don't line up properly you might have door issues.....good luck

carwash · 12-19-2016, 08:15 AM

I have wrecked and abused car issues.... that's for sure.

sballard · 12-19-2016, 08:50 AM

This will probably help you out...

Porsche Classic Genuine Parts Catalog - Porsche Cars North America

It should have the bolt sizes in the schematics