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Rasta Monsta · Joined: 12 Jul 2006 Posts: 11733 Location: PacNW

This is a topic needing no introduction, as many of us have struggled with "separation anxiety." Shaggy's hatch was in good shape except for glass pulling away from the frame in the hinge area, as typical. So, I embarked on the adventure to remove the frame completely from the glass and reseal it with 3M "Windowweld."

The first step is to remove the three sections of the 931 spoiler. I found this easier to do with the hatch still installed. I dremeled a 50 cent screwdriver to fit the odd nuts holding on the left and right sections.

With the "correct" tool, the side sections came off easily.

My car has the "extra" seal along the trailing edge of the hatch, held on by two of the spoiler screws and glue. This must be removed to expose all of the philips screws which secure the middle section of the spoiler.

As noted in the FAQ, these screws are quite soft, and prone to oxidizing. Only one offered resistance, and it was removed using my cordless drill on a low-torque "impact" setting and philips bit.

Next the latch pins come off. These screws are also much too soft, so it is important to use a philips head that matches them. My hand impact tool fit the bill (no, I didn't use a hammer).

Now the hatch can be removed from the car and brought into the living room. There is one more piece of trim that needs to come off, along the top or leading edge of the hatch. It has tabs at either end that can be gently pried open, then the strip comes free.

Now comes the fun part. The glass simply lays in the frame, but there is a rubber seal in between. I have read in various places that there is no adhesive used during factory assembly, which may be the case, but the glass is stuck to the rubber regardless. Use a putty knife to work your way along the frame, slowly separating the glass from the rubber seal. Gently prying with a screwdriver, speeds the process.

I must urge caution here. Glass is a miraculous substance, with incredible strength given its thickness and transparency. However, it is also highly vulnerable to lateral or torsional stresses, which can lead to disaster.

Like this:

Lock the dogs in the bedroom and get a dustpan. Prepare to find glass all over your house for days. Don't let your wife take the towels outside and "shake them out" like Shari wanted to - there was a substantial amount of the remains that was reduced to particles finer than sand - extremely dangerous.

Now look on Ebay.

It's a miracle! A 944 hatch in near perfect condition right here in Portland for $75. . .the guy even brought it over, and it doesn't leak a drop! I had reservations about the 944 spoiler, but it looks hot. . .the 931/924s spoiler just looks wimpy by comparison.

So, there you have it, a perfect reseal. Just be sure you are prepared to deal with all contingencies if you embark on this project!
_________________
Toofah King Bad

WeiBe (1987 924S 2.5t) - 931 S3

Paul · Posted: Fri Mar 09, 2007 10:34 am Post subject:

Man that sucks, but your write up is funny, LMAO!!!

This should be moved to a newly created section named:

HOW NOT TO
_________________
White 87 924S "Ghost"
Silver 98 986 3.6l 320 HP "Frank N Stein"
White 01 986 "Christine"
Polar Silver 02 996TT. "Turbo"
Owned and repaired 924s since 1977
Porsche: It's not driving, it's therapy.

pocketscience · Posted: Fri Mar 09, 2007 2:24 pm Post subject:

I have just one question... How many times did you say "f*ck!"?

Gavin.
_________________
Whoever said you can't buy happiness forgot about Porsche!
81 924 N/A, GTS lights, Saratoga, interior, headers, Integral cam, EFI (sold)
95 993
69 911

steeny · Posted: Fri Mar 09, 2007 2:33 pm Post subject:

given the cost of hatches in the US, i've no idea why you would try and fix one....

over here, thats a $600 mistake
_________________
1978 924 N/A
she's gone.....

Rasta Monsta · Joined: 12 Jul 2006 Posts: 11733 Location: PacNW

pocketscience · Posted: Sat Mar 10, 2007 7:21 am Post subject:

I guess given steeny's comment on the relative prices "f*uck" is more appropriate here... for $75 it's a mere "d'oh"

G.
_________________
Whoever said you can't buy happiness forgot about Porsche!
81 924 N/A, GTS lights, Saratoga, interior, headers, Integral cam, EFI (sold)
95 993
69 911

Peter_in_AU · Joined: 29 Jul 2001 Posts: 2743 Location: Sydney, Australia

wow!! That is a great how-to. Really easy to follow and the photos are great. Serves as a good warning for those of us who live in places where $75 hatches are just a dream.

So, what actually caused the glass to explode?
_________________
1979 924 (Gone to a better place)
1974 Lotus 7 S4 "Big Valve" Twin-cam (waiting)
1982 924 (As featured on Wikipedia)

Learn to love your multimeter and may the search be with you

Rasta Monsta · Joined: 12 Jul 2006 Posts: 11733 Location: PacNW

This prying action...I was twisting the screwdriver blade against the edge of the glass to coax the frame loose, and ka-BLAM.

_________________
Toofah King Bad

WeiBe (1987 924S 2.5t) - 931 S3

leadfoot · Posted: Sat Mar 10, 2007 11:44 am Post subject:

So do you think it's still possible to get the frame off without destructor being let loose in the house, mabye a womans touch is needed.... Shari honey, what are you up to?, Iv'e got a favour to ask...!!
Leadfoot
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1981 ROW 924 Turbo -
carbon fiber GT mish mash
LS1 conversion in progress...

Rasta Monsta · Joined: 12 Jul 2006 Posts: 11733 Location: PacNW

Send her a ticket. . .she's been waiting to see Melbourne.
_________________
Toofah King Bad

WeiBe (1987 924S 2.5t) - 931 S3

steeny · Posted: Sat Mar 10, 2007 5:52 pm Post subject:

I have to do this job really soon, probably before winter sets in, and i'm not looking forward to it really. esp now that i've seen what can happen.

reminder to self....be verry, verry careful.
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1978 924 N/A
she's gone.....

Nobbi · Joined: 24 Aug 2006 Posts: 1396 Location: Germany

Hello,

we funny and lucky people in europe simply visit a Renault dealer order the rear glass of a Renault Fuego and get a 924 rear hatch glass for almost no cost.

Nobbi

pocketscience · Posted: Wed Mar 21, 2007 10:15 am Post subject:

Hmm, it's exactly the same glass?? All models/years?? The Fuego was available here in Australia for a while...

Cheers,
_________________
Whoever said you can't buy happiness forgot about Porsche!
81 924 N/A, GTS lights, Saratoga, interior, headers, Integral cam, EFI (sold)
95 993
69 911

steeny · Posted: Wed Mar 21, 2007 11:18 am Post subject:

pocketscience, i think you read my mind

might be time to check out some wreckers and see if they have any in the yard
_________________
1978 924 N/A
she's gone.....

fiat22turbo · Joined: 18 Jan 2006 Posts: 4040 Location: Portland, OR

The Fuego was sold in America as well, not that very many of them actually sold nor are many of those still around.