Porsche 911 SC Wiring Repair Project

Spring has finally sprung in the UK. The weather here was a balmy 12 degrees this afternoon, so I took the opportunity to get stuck back into the jobs on my Varmint Porsche 911 SC after two months with no activity.

The last thing I touched on this car was the fusebox. The fuel pump relay wiring looked a little scary, as well as some very corroded main terminals on the battery, and some melted insulation in the ECU loom (the US cars run a little ECU). Today was all about repairing and digging a little deeper.

First job was to repair the fuel pump loom. I chopped out the solder blobs and installed DuraSeal connectors, with a few soldered joints here and there. Rough-looking wiring was replaced with matching genuine Porsche cable. The beauty of breaking a 924 and a 944 (and stripping out all the wiring) is I now have a lifetime’s supply of proper copper. I also took the fuel pump relay apart and found the contacts pitted and slightly bent. I cleaned and realigned all that and then resealed the cover.

Fusebox refitted, I got to sorting out the ignition switch feeds from the positive battery terminal – they were in a right state. To do it properly, I pulled the (huge) battery out completely and was relieved to see the tray and surrounding metal work absolutely rot free. This car is so tidy! I cut these out and replaced the lot.

Finally for today, I boiled up the battery earth lead to rid it of verdigris, dried it with heat and drowned it in switch cleaner. I tidied up the battery posts and terminals with my cool new battery tool, fitted a Dis-car-nect for safety’s sake and stripped all the earth points back to bare metal. Everything went back together a treat.

There was nothing much wrong with the way the SC worked before I took it apart but, as the pics show, it has a bit of classic old Porsche wiring syndrome going on, so it all needed doing. Hopefully I am adding reliability: if I can get it registered this week, then I am considering taking it to Germany for the Techno Classica in Essen in ten days’ time. Fingers crossed!

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