DDK - Die Deutschen Klassiker

Hi guys, I need to replace my jack receiver tube on one side....

Does anyone know how and where the jack receiver tube (not the outer bracket) is welded in? From all my digging and looking at photos online, it looks like the flat end might be welded to the underside of the floor, and possibly just inside the car (and possibly accessible in that case).

Can anyone say for sure where the tube is welded, and if I can I get to those welds and replace the tube without removing the inner sill ?

Thanks in advance for any help you can give!

It’s a bit hard to find but it’s welded to the inner inner sill (many layers!) in the area ringed in this picture. Ignore the massive seatbelt reinforcing welded over the top on my car.

Extracting it will be challenging and I’d imagine if the tube is rotted there’s lots more going on in there.

The receiver bracket pushes over the tube from the outside and the flattened part of the tube is wider than the square hole in the bracket. So you’ll have to remove the receiver bracket to get it out.

Best of luck. This won’t be fun.

Thanks for the tip - I thought it might be somewhere in that 'area'

I've done a bit more digging online to try to locate the welds more precisely. I think I can see where the weld points are now, see my pics.

- does anyone how if these were spot welds, plug welds or bead welds?

Once I clean off the paint in that area adjacent to the seat mounting rail section, and inside those wee bumps in the floor section, hopefully I will be able to see how and where the tube was attached..

Just found out how the tube is connected to the floor section from the pics in this thread... http://forums.pelicanparts.com/porsche- ... ion-4.html

Big plug weld inside the car if I remember correctly, and yes also welded to the floor edge.

You can see from that thread how hard just doing the tube is going to be as the support goes up inside the outer sill.

Ahhh, but I have a cunning plan Gary - please let me know what you think...

0 - cut out section of outer sill to provide access to the whole jack bracket area (done)
1 - drill out jack tube middle attachment to floor with (my large) spot weld cutter.
2 - slot the sheet metal immediately ahead of the bead weld inside the car, as shown.
3 - remove the jack tube outer bracket, and with/then the jack tube (with help of chisel if necessary).
4 - check the integrity of the metalwork around the tube with borescope and cut and TIG in new sections if needed.
4 - file the end of the new tube to fit snug against the old weld bead + trim the slot as needed to weld through it.
5 - hold the new tube and bracket into final positions.
6 - MIG weld the end of the new jack tube to the old weld bead (and close the slot at the same time).
7 - plug weld the middle of the tube to the floor, as per original.
8 - attach new jack tube outer bracket.
9 - TIG new metal in flush to the outer sill section that was removed to gain access.
10 - stand back and look really smug.