Hot!Boxster Cayman undertray stud repair nut

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chaz1 PCGB Member
2017/09/19 15:45:29 (permalink)

Boxster Cayman undertray stud repair nut

If you are unfortunate to snap a under tray stud it happens quite often on some older cars.
Porsche unfortunately are low volume manufacture and exempt from some EU rulings.
Therefore they not have to supply this part at all.
The best the OPC's can do is replace with a nut and bolt which is still  expensive as the seats and carpet need to come out.
Having tried two methods the disc stud and the repair nut both seem ok.
Still have to do some high speed tests but the repair nut can take more load than the original Porsche nut before failure so it looks good.
I have now printed a 3d ABS replacement repair nut that saves on you having to replace the body shell attached stud if it does snaps.
The stud usual snap where the nut is attached due to water being held in the coarse thread causing corrosion and weakening of the stud at that point.
When you try to remove the nut the stud shear at the weakest point so always use a penetrating oil cleaning the external thread with a brass brush
The repair nut has a long cylinder of tread above the nut flange which will pass through a slightly enlarge (by 1mm) hole in the undertray.
As the thread is longer it can reach the remaining thread.
It must have at least 65mm of thread left on the broken stud to  provide a good fix.
The repair nut is considerable stronger and flange disc is slight greater by 2mm to 25.5mm
The repair nut is designed to tighten to the body shell to prevent water ingress into the thread but this can not be guaranteed.
So  you need to cut to size with Dremel hacksaw.
The part has been tested to destruction for load against the original Porsche part.
The modified part survived much greater loads than the original part  due to being made with stronger material ABS.
The Porsche part is polypropylene based so quite soft but it is effective for its intended job.
You will need to to cut the thread on the repair nut with a remain stud asPorsche were not able to advise thread size .
Torque to the standard setting for the Porsche part
It can be made in glow in the dark ABS if that takes your fancy :-)
Hopefully you will never need one but if you do shout.
post edited by chaz1 - 2017/09/26 15:44:39

4 Replies Related Threads

    PCGB Member
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    Contraband PCGB Member
    Re: Boxster Cayman undertray stud repair nut 2017/09/19 17:12:52 (permalink)
    Any pictures?
    Guest of the Club
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    Guest Guest of the Club
    Re: Boxster Cayman undertray stud repair nut 2017/09/19 17:56:26 (permalink)
    how much per nut?
    PCGB Member
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    chaz1 PCGB Member
    Re: Boxster Cayman undertray stud repair nut 2017/09/20 18:24:05 (permalink)
    post edited by chaz1 - 2017/09/20 18:30:05
    PCGB Member
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    chaz1 PCGB Member
    Re: Boxster Cayman undertray stud repair nut 2017/09/20 18:40:28 (permalink)
    This is a prototype part  a cleaner print will be done
    post edited by chaz1 - 2017/09/20 21:16:16

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