Most stupid annoying task to handel on a 911

[Flojo]

As most may have noticed, I'm rebuilding my car. Disassembly is always "easy"...
During the reassembly though you have to tackle all kinds of tasks and some are absolutely frustrating as you first don't get it how it is supposed to be/sit in place, takes time to figure out and then it needs multiple attempts to get it right.

I'm actually quiet clever (most of the time) and I work things out, but here's one troublemaker I start the list with for you all to chime in:

The gas tank rubber nozzle around the filler neck builds a bridge between the fender and the inner body. Opening the gas flap you see the wide opening of the rubber nozzle. The opening sits in a 360 slid secured by a large metal spring ring.

Whichever way I attempt the install this spring ring in that limited space, I just can't snap it in place.
Second attempt tonight. If you here a scream then it's due to victory or because I damaged the fresh paint.

Maybe you have similar stories to share about what made you go near mad.

[thetorch]

Anything having to do with the blower assembly, but especially:

Pass through rubber grommet for heater tubes passing from footwells into front trunk control box / diverters. Positioning them flat, correctly before or after installing the tubes was impossibly unpleasant.

Installing cables for heater / blower / fresh air box. Finicky beyond belief to route them without a harsh bend, getting the orientation of the lever end side correct, and the back and forth of adjusting them.

[911SauCy]

Running new fuel lines through the tunnel at home is always a treat.

So is reaching down and trying to get the lower pin through driver side hood strut.

[GH85Carrera]

The one thing I HATE about my 85 Carrera is getting the air cleaner back together. The back clips are a pain, the bottom rear clip is almost impossible.

I have a zip tie attached to the back side clips, and I can grab those with a finger and get them on, but it chews up my arm.

[3rd_gear_Ted]

To get @ one bolt & nut for each G body front fender, the door needs to be removed.
Two of the nuts & bolts for the front fender can't be accessed because of the oil lines being installed after the front fender was installed.

[mo-mon]

Flojo, this video might help you-https://www.youtube.com/watch?v=EcZfuXIiRK8

[thsupernge]

Originally Posted by GH85Carrera

The one thing I HATE about my 85 Carrera is getting the air cleaner back together. The back clips are a pain, the bottom rear clip is almost impossible.

I have a zip tie attached to the back side clips, and I can grab those with a finger and get them on, but it chews up my arm.

It's the worst. I lowered the engine about an inch and its manageable...otherwise impossible for my meaty shirt hangers.

[panzerfaust]

That’s not good news... doing the tunnel lines and the rubber filler boot next ��

[wareaglescott]

Still wake up sweating occasionally thinking about getting that wiring harness in and out of the center tunnel.

[Larmo63]

Sometimes things go wrong right at the time you are ready for the project to come to an end because you
want to DRIVE THE &%$#)@!?% THING!!!!

At least we're all rooting for you!

[Kidasters]

O-rings on the engine mounted oil cooer.

[fanaudical]

High on my list of frustrating Porsche experiences:

- Installing RSR rocker shaft seals without shaving them off during insertion

- Installing hood strut lower pins

- Removing the cigarette lighter

- Removing the rear suspension arms with the engine still in the car

- Trying to get the wipers to park correctly

- Finding that rattle in the driver's door

[pmax]

What's the trick to aligning that transmission mount ?

[Showdown]

Anything and everything behind the dash or having to do with the convoluted vent blower system.

Also Porsche electrical while we’re in WTF territory.

[Ian Comerford]

Fitting a new rubber seal between the oil tank and inner wing, it’s really difficult to apply enough pressure to compress the rubber and get the nuts started.

[Flojo]

good listing so far guys!

Originally Posted by mo-mon

Flojo, this video might help you-https://www.youtube.com/watch?v=EcZfuXIiRK8

lovely to watch, but no, he skipped on how to install tat spring ring.
never mind. I may probably leave it off anyway

Originally Posted by fanaudical

- Finding that rattle in the driver's door

for me I discovered that a rubber support from the door lock mechanism was gone and rattled against the inner door tin.
solved that with a small bit of rubber hose.

[Url]

Installing the clutch cable clevis pin annoys me every time ...

[AlKidd]

I had to pull in re-enforcements with tiny hands to do the lower pins for hood struts but my worst so far was the re & re of the pedal assembly and all the connected bits.

[Fubawu]

Ignition switch...was a major pain. Can't see anything, all by feel. Your hand in some sort of carple tunnel developing position.

[chrisbruck]

Changing a headlight bulb and getting the H4 headlights to stay in place with a new fender gasket....

Oh and don't get me started on the weird spring clip thingies that hold a new glass headlight lense to the housing...