Heater Flap Fix

I noticed that when just driving around in the 944, regardless of whether my heat was on, my vents would blow hot air. Thankfully it turns out this is a common failure mode. The clip that holds the rod for the heat flap breaks causing the rod that actuates it to fail open (so you don't freeze in Germany during a failure). The actuator is located behind a plastic cover under the dash and you just have to replace the plastic clip and retainer, reattach the rod and you're good to go.

Broken heater flap rod clip

Clip and retainer replaced

Maintenance Update:

Mileage: 99,056

- New heater flap clip and retainer

Oil change for the 944

I realized it’s been a bit longer than usual since my last oil change on the 944. I had meant to do it last year while other work was being done but I must’ve forgotten so no better time than the present. 

Oil change time

Maintenance Update:

Mileage: 99,055
- 6 quarts Valvoline 20W-50 VR1
- Porsche/Mahle OC142 oil filter

9ElevenHeadlights Raven Headlights

During the first iteration of the 911SC build, we installed LED headlights from Audette Collection with Bosch fluted lenses along with an H4 harness conversion. While aesthetically it looks great, to be frank, I found the lights to be dim and a bit scary to drive at night. I wanted to get something that was really well engineered and have been eyeing 9Eleven Headlights for some time now. 

9Elevent Headlights Raven headlights in Gunmetal

The headlights are an engineering work of art and while they are quite pricey, I'm more than happy to support small business who do things the right way. Installation was pretty straightforward since I already had LED lights before with the H4 conversion. The kit came with a harness that connects to the H4 socket and then their connector on the other side that goes to the headlight.

H4 adapter harness

I also got fresh headlight gaskets. Even though my old ones were still fine I figured it's cheap enough to put a fresh set in. I've never bought anything that actually included white gloves to ensure you don't mess up the lights during install. 

included white gloves

The lights look absolutely gorgeous installed and the brightness is spot on. I opted for black headlight rings and I think it gives a nice aggressive look.

Raven gunmetal headlights installed

Raven gunmetal headlights installed

Lights on

Audette Collection headlights (left) vs
9Eleven Raven Headlights (right)

Coolant Sensor Fix and New Battery

For a while now at cold start I'd get a temporary "Failure Detected" message on the Cayman with the coolant temp gauge showing no value. Once the car warmed up, this would go away. After some research I found that this is a symptom of the coolant temp sensor going bad. Given that the car is now 19 years old, I suppose that's not completely unexpected. 

New coolant temp sensor, o-ring and reitaining clip

I ordered a new OEM sensor along with a new o-ring and retainer clip, dropped the car off with Lee at Hybrid Motors and he made quick work of replacing it and topping off the coolant. Unfortunately on my way home after picking it up, I got a nice bullseye from a rock and cracked my windshield. I used a Permatex repair kit to prevent further spreading for now but I will probably get the windshield replaced once I find a place I can trust to replace it with OEM glass. 

Cracked glass

Attempting a temporary repair using a Permatex repair kit

My Antigravity lightweight battery is also approaching 7 years old and while it's still fine, I don't want to run the risk of a battery failure when I'm out somewhere due to age so I pre-emptively bought a new 40Ah version to replace it.

New Antigravity Battery

Maintenance Update:

Mileage: 56,258

- New Antigravity 40Ah battery

- New coolant temp sensor, o-ring and retainer clip

New Seat Foam for the 944

The interior on the 944 is actually really clean and original. The only thing after 35 years is that the driver side seat bolster flattened over the years so I wanted to actually fix this to make things 100%. Unfortunately finding brand new OEM seat foam is difficult, if not near impossible, so I bought some new seat bottom foam from Design911 in the UK.

Seat out of car with new foam next to it

New foam

The only problem with the new foam is that it’s a bit generic for the standard seat so it’s not a direct replacement. It doesn’t have the appropriate cut outs for the power seat controls nor and doesn’t match all the contours needed to slot in to the seat frame.

Removing the seat cover and cushion from frame

New seat foam vs very old one

I spent several hours cutting and trimming the new foam to match the old foam then recovered and attached everything back to the seat frame. It was frankly way more work than I thought it’d be but not only does the bolster look better, the fresh foam makes the seat feel much better and supportive.

All the foam trimmings

Seat bottom frame

Everything put back together

End of Season Oil Change for Kay

Unfortunately, colder days means we're at the end of the season so time to change out the oil on the Cayman to make sure it doesn't just sit in contaminated old oil all winter. I let the car drain for a whole day so it seems more oil came out of it than usual so it took a full 9 quarts to get it just under full (I've got the FVD motorsports oil pan that adds about 0.7 quarts oil capacity so it's a bit more than stock). 

oil change time

Maintenance Update:

Mileage: 56,021

- 9 quarts Driven DT-40

- NAPA gold filter

End of Season Oil Change for Scarlett

End of season means time to start to clear out old oil and any contaminants before the car sits for long periods.

Oil change time

Maintenance Update:

Mileage: 174,303

- 11.5 quarts Driven GP-1 20W-50
- Mahle OC54 oil filter

Suspension refresh for the 944

I haven't been doing any motorsports events in the 944 because it developed a bit of a clunk when stopping at slow speed and the alignment wasn't what I wanted. I decided to get a fresh set of Konis and I'm glad I did since it turned out the old Koni front inserts started to have play in it. We reused the ground control coilovers that were already there and obviously the Racer's Edge camber plate that was also installed earlier this year. 

New front Konis installed

Rear Konis installed

I was also not happy with the uneven ride height so I had SJF reindex the torsion bars in the rear which unfortunately is easiest to do by dropping the entire rear and also had the front lowered a little bit. 

Reindexing rear torsion bars

The result was much more even ride height

LF - 25 1/2

RF - 25 1/2

LR - 25 5/8

RR - 25 1/2

The alignment was then properly done with the front camber maxed out. The rear is set 1 degree less, 0 toe and dialed in a little toe out in front to get better turn in.

We also noticed an oil leak from the plugs in the valve cover so new seals were installed. We also replaced the completely destroyed exhaust gasket. We then discovered the source of the clunk. The bracket that sits above the exhaust in the transmission tunnel wasn't fully tight. As soon as that was tightened, the clunk disappeared. 

Maintenance Update:

Mileage: 98,728

- New valve cover gasket and plug set

- New exhaust donut

- New Koni yellow all around

- New bolts and hardware for struts

Little End of Summer Autocross

Well we haven't  had many local NNJR SCCA Autocross events for a few months now since Metlife stadium has been busy getting ready for the FIFA World Cup. We finally got one today for the last one before the summer and our friends go off to Lincoln to duke it out at Nationals. 

NNJR SCCA Autocross - 8-24-2025

Weather really couldn't have been better, pretty much high 70s to low 80s all day with some cloud cover and a decent breeze. Course was fast and fun and the Cayman's feeling nice and spicy and dancing around just the way I like it. It's funny because I drive the S2000 a lot on track of course which is far more scary in terms of kicking out the rear so when the Cayman does it which feels very slow and controlled, I find it super easy to drive through. Kept the tires at 30psi all around hot and that felt pretty good so I think I'll stick with that. 

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NNJR SCCA Autocross - 1st place XSA - 57.692

Joe Engineering NACA duct

I've had the Achtungcraft air duct for the oil cooler on Scarlett for some time now and the screen has started to come off. I've also unfortunately hit it with my knee a few times when walking around the car. I saw the new NACA air duct from Joe Engineering and it looks much better. It's streamlined into the bumper so nothing is protruding and funnels air nicely to the oil cooler. I ordered the premium version which has a nicer finish and made of better material. 

Joe Engineering NACA duct

Joe Engineering vs Achtungcraft

Install was super easy and just took a few minutes since I had already removed the side marker before to install the Achtungcraft duct. I made some suggestions to Jose about how to improve on it a bit in the future but overall a nice piece.

NACA duct installed

First autocross in a year

It was May 11 of last year when I last autocrossed, which was in the 944. Obviously feeling super rusty so enlisted my equally rusty friend, Rad, to codrive with me in the Cayman. We had a fun little battle where he got me on his last run but I was able to find a bit more time to take the win on my last run. Good times, great weather, loads of fun. I definitely miss this.

NNJR SCCA Autocross - 5-18-2025

The Motocompacto also made an appearance
Photo by: Autox4u

Run comparison

Pre-autocross maintenance

Not only has it been over a year since my last autocross but it's been even more than that for the Cayman. I signed up for the NNJR SCCA autocross on Sunday but since it's been over 2 years since I changed the transaxle fluid and brake fluid, I wanted to get that sorted before any kind of actual performance driving. Went to see SJF Performance to get this all sorted. First was a full flush of the brake fluid with Motul RBF600.

Fresh Motul RBF600

Fresh Motul RBF600

Next was fresh Motul Gear Oil for the transaxle. The oil fluid actually came out super clean, still the same blue color this fluid comes in from the bottle so there's definitely no excessive wear on the OSGiken diff inside it.

Motul SAE 75W150 gear oil

I also wanted to see of my Honda Motcompacto could fit in the trunk and was pleased to see that it did so I can take it to events to get around.

Motocompacto in rear trunk of the Cayman

Maintenance Update:

Mileage: 54,100

- 1.5L Motul RBF600

- 3 quarts Motul SAE 75W150 gear oil

High Performance Water Pump

A common failure point on the 987/997 is the water pump. The impellers eventually wear out and disintegrate. The good news it that the impellers are plastic and don't damage the engine if it goes but it could clog somewhere and cause cooling issues. The best way to avoid this is preventative maintenance and replacing it regularly. One of the previous owners of my Cayman replaced it at 25K miles but that was many years ago now (close to 10 years) so I figured it was time for me to do the same just for peace of mind. I went and got an FVD high performance water fuel pump with a plastic composite impeller. The kit included new gaskets and a lower temperature thermostat.

FVD High Performance water pump with plastic impeller

FVD High Performance water pump with plastic impeller

Lower temp thermostat

Lee at Hybrid Motors made quick work of this and obviously changed the coolant as well. The condition of my old pump was good. No chips or missing pieces from the impeller so that's always a good sign that everything is healthy.

Maintenance Update:

Mileage: 54,007 miles

- New FVD High Performance Water Pump
- Lower temp thermostat
- New belt
- New coolant

Racer's Edge Camber Plates

One thing I wanted to fix on the 944 was the ride height. The rear sagged too much and the fronts were too high. I also didn't have enough camber. To fix this I bought a pair of Racer's Edge camber plates

I took the car to Lee at Hybrid Motorsports and had him install it along with reindexing the rear torsion bar (which I'll note appears to have already been upgraded to 27mm at some point) to raise the rear for a more even ride height.

Maintenance Update:

Mileage: 98,271

• Racer's Edge camber plates
• New OEM caster blocks
• Rear ride height raised
• Alignment

Oil Change on Scarlett

Finally getting a break from the snow. Time to prep the cars for Spring starting with an oil change for Scarlett.

Maintenance Update:

Mileage: 173,690

- 11.5 quarts Driven GP-1 20W-50
- Mahle OC54 oil filter

Pre-Winter Cayman Maintenance

Weather is getting colder and starting to see salt on the roads to it's time think about packing up the cars for the winter. In preparation, time to get the old oil out of the Cayman and put in the fresh stuff.

Maintenance Update:

Mileage: 53,870

- 8.5 quarts Driven DT-40
- NAPA gold filter

Weird battery drain on the 911

For the past few months I noticed something odd, every now and then I'd have the 911 on my CTEK charger but it'd throw an error that the battery wasn't holding charge. I figured that my battery was just dying but it's really only been 3 years. Still after the battery just wouldn't charge anymore, I bought a brand new battery and noticed the same thing was happening. I decided to check for any draw on the battery while the car was off and key out of the ignition and it measured 370mA. That's way too high especially for an "old car" with barely any electronics.

370mA of draw

I unplugged every fuse and relay from the car and nothing changed. This was bizarre. I eventually gave up and took it to Lee's Autowerks so he could get to the bottom of it. He eventually found the source of the problem but it wasn't the usual suspects. For whatever reason, the ignition switch had become faulty and the contacts terminal 30 and terminal X was closed (on) all the time. You can see in this video comparing it to the a new ignition switch (later installed in the car) that those contacts should be normally open.

Faulty ignition switch (left) vs new normally working one (right)

With the new ignition switch install and key out of the car, you the draw is now only 35mA which is well within the 100mA max static draw noted in the service manual. Big thanks to Lee for getting this all sorted so I don't have to worry about the battery just dying on me if it's not on a tender all the time.

35mA static draw with the new ignition switch

Maintenance Update:

Mileage: 173,397

- New ignition switch

Fixing oil leaks and replacing fuel pump on the 944

I was continuing to have oil leaks from both the front and rear main seals on the 944 so I took it to Lee Autoworks to have this fixed once and for all. He found the crankshaft to having about 1.4mm of play which is well outside of tolerance which should be less than 0.4mm so we agreed to pull the engine out and have a closer look. 

Engine out inspection on the 944

The thrust bearing had excessive play and since the engine was opened up anyway, I had him check everything else out. There was a tiny bit of wear in the conn rod bearings and main bearings. Nothing to be super concerned about but I opted to have it all replaced along with all the seals since I don't want to have to do this all over again.

Fresh parts are here

I also took this opportunity to have the fuel pump, fuel filter, in tank strainer and hoses replaced so that I have peace of mind. I had no record of it ever being replaced and given the car is 33 years old I didn't want to have to second guess the fuel system so it seemed like a prudent thing to do. It did seem like it was replaced at some point so perhaps this was unnecessary but at least I know now exactly when it was done and it'll be happy for years to come. The crankshaft and camshaft position sensors also tend to go bad on these cars and given its age, I also had both replaced with new ones. 

He also go to the bottom of why the car kept stalling or having a no start condition. The connector for the mass airflow sensor was loose causing it to sporadically disconnect. He tightened up the connectors so it would have a firm electrical connection and now it starts like a champ every time. 

Engine back in and fully functional

People say these engines are some of the smoothest 4-cylinders ever made and while it was fairly smooth before now I really understand what they mean. At any RPM the engine is hyper-smooth with good power delivery. Such a joy to drive!

Maintenance Update:

Mileage: 97,356

- 6 quarts Valvoline 20W-50 VR1

- Mahle OC142 oil filter

- New OEM fuel filter

- New OEM fuel pump

- New OEM in-tank fuel strainer

- New OEM fuel hoses to fuel pump

- New OEM main bearings

- New OEM thrust bearings

- New OEM connecting rod bearings

- New OEM oil pickup tube

- New OEM crankshaft  position sensor

- New OEM camshaft position sensor

- Fresh antifreeze

- New engine seals