DIY RS-style doorpanels

Here are some pics of the interiour of our 911. A DIY description on the RS-style doorpanels (including part#'s) is at the botom of this page...



DIY 911 RS-style doorpannels:
Building your own RS-doorpannels is a pretty straight forward job (heck even I could do it!) You can use either your current doorpannels (or get a cheap set of used ones) and take of the bins, handle and upholstry, or you can make complete new ones out of a $ 0.50 piece of hardboard, which will take some extra fiddling (but again, I did it therefore so can you). If you decide to make new ones, just copy the originals as precise as possible.

Depending on your preferences and/or goals (weightsaving, a more 'racey' look or both) you can decide weather or not you want to keep your doorspeakers and electric windows.

Next you will need a new doorhandle, opener-strap, strapguide and some mounting hardware. I guess you could find something quite similar somewhere else for a lot less, but if you want your doorpannels to look like the real thing you'll have to get original Porsche parts. These will set you back about $ 250 (for both doors, so you're still $250 ahead of buying 'ready-to-install' pannels somewhere else).

The parts & partnumbers:

- door opener 'pull-straps' 964 555 832 00 N13 (1 for each door)
(N13 is the colorcode for red, but these also come in black or blue)
- strap-guides 964 555 761 00 01C (1 for each door)
- doorhandle (leather) 964 555 251 00 8YR (1 for each door)
- 'rosette' 964 555 761 02 01C (2 for each door)
(these look like the strap-guide, and hide the mounting hardware of the doorhandles)

Recommended mounting hardware (must have!):
- 999 531 014 02 (1 for each door)
- 999 166 040 02 (1 for each door)
Also get some new plastic 'push-pins' that connect the pannel to the door, 'cause the old ones will probably break or be sloppy (sorry, no partnumbers for these, shouldn't be a problem though).

You'll also need some bolts, nuts, washers and spacers to mount the doorhandles, but you can get these at any hardware store or probably have them in your garage already.

Ok, you're ready to party!
If you make new pannels out of hardboard, make 100% sure they fit like the old ones do (this comes pretty close!). Try and mount them, you'll be more happy afterwards.
Next you'll have to figure out where to mount the new doorhandles. In pre 964 cars this will require drilling some holes. You may also be able to use the mounts of the window mechanism by replacing the allenbolts with longer ones. Take your time to figure out the most solid setup (remember these doors are heavy, you don't want to distort the sheetmetal by pulling the doorhandles when you close the door). If you drill extra holes, put some paint on it and remove all filing that falls into the door. Water gets in your doors and you don't want things to rust. Also for waterprotection leave the plastic that you find in your door in it's place and patch it up if neaded (water will do funny things with hardboard).
Next figure out where the pull-strap and strap-guide have to be located. Mind that the strap operates at an angle which differs when you pull it.
The location of the 'locking-knob-dishes' can be a bit of a challenge. Notice that you'll have to use foam on the backside of the pannel so it's push nicely against the edge of the dish.
Check at each step if everything still fits. This will take some time, mounting and removing everything over and over again, but I can't say it enough, you'll be very unhappy if you think you're finished and it turns out you're just a couple of mm's out of spec.
Once you're 100% sure everything fits, take it all apart again untill you only have the piece of hardboard. Now your ready to apply the upholstry material. You can have it done for you or you can do it yourself. Because it's all flat, it's a pretty straightforward job, but you may consider to leave it to a pro since it determines the final look of you doorpannel. Make sure to use a thin foam between the pannel and the upholstry or use an upholstry which already has this foam.
Take a good look at your original doorpannels to see how the upholstry is applied. It might look like it's only stapled at the edges, but use glue on the surface of the hardboard too (you'll have very sloppy looking doorpanels if you don't). If possible get a set of those plastic edges that are stapled on the backside of the pannel (or use the ones on your old pannel) this will look a lot nicer.
Don't forget to glue some foamblocks on the backside of the pannel. These work as spacers (e.g. at the dish of the lock-knob) and prevent the pannels to rattle.
Well, that's it, you're ready now for the final mounting.

Goodluck!

If you have any Q's, feel free to send me an e-mail