The Cayman and Boxsters are nearly perfect cars, but the design of the rear quarter panel allows dirt and gravel to kick-up from the tires and scratch the paint. As there does not appear to be any commercial products suitable to address this issue, I created my own.
Here's the process:
1) Find some suitable material to use as a mud guard. I bought some scrap 1/8" thick black plastic from a glass supply house in my town, about $2.
2) Create a template on heavy paper by holding it in place inside the wheel well, and creasing the paper with your fingers against the inside lip of the quarter panel to get the inside profile. Then sketch the desired outside profile on the paper, and cut out the results with scissors.
3) Lay the paper template over the plastic, and outline the two mud guards, mirror images of each other.
4) Cutout the rough shape with a bandsaw or other suitable tool.
5) To get the shape right, sand the edges using a drum sander and a spindle sander. Sand paper wrapped around wood blocks would work just as well.
6) Drill holes in each completed mud guard, about 2" down from the top, and 3" up from the bottom, 1/2" in from the inside edge.
7) To mount the completed mud guards, raise the side of the car and remove the rear wheel. Clamp the mud guard in position on the rear quarter panel lip (using a loose vise grip, or other type of clamp.)
8) Using the initial holes in the mud guards as guides, drill slightly larger holes suitable for #10 screws through the mud guard and through the lip of the quarter panel. No worries, it's only plastic!
9) Using 10-32 x 1/2" stainless steel flathead screws, washers and nylok nuts (or metric equivalent), attach the mud guards through the holes. If you need more romm behind the lip, remove the two heat guard screws on the bottom lip of the rear quarter panel and push back the heat guard from the inside lip.
10) Repeat for the other side.
11) Here's how it looks installed:
(Here's the scanned template I used)
Enjoy!
Tom..
Linear Mode
