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YOUR RESEARCHRepairing a broken roll bar windscreen tab - 986 Forum - The Community for Porsche Boxster & Cayman Owners
Leading reported evidence
Use rivet
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No successful repair reported for this finding.
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Repairing a broken roll bar windscreen tab - 986 Forum - The Community for Porsche Boxster & Cayman Owners
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Leading evidence: 'Use rivet' (no explicit attributable resolution; this is a reported action or suggestion). Across 1 matching discussions, The most frequently discussed action is 'Run from the outside of the windscreen' (1 discussions). For that action, 0 discussions report a resolution and 0 report an unsuccessful attempt. No action has an explicit, attributable resolution report under the current rules. These are forum reports and suggestions, not a confirmed diagnosis.
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Explicit resolution reports before identified causes, performed actions and suggestions. Within each level, matching component labels precede direct query mentions and inherited thread context; successful versus unsuccessful discussion counts, owner confirmations and independent discussion support determine order. This is not a probability of success.
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Performed · outcome unconfirmed
It's not nearly as creative, but I just used zip ties on my friends 986.
Repairing a broken roll bar windscreen tab - 986 Forum - The Community for Porsche Boxster & Cayman Owners
Run from the outside of the windscreen
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Suggestion · Original poster
The rivet should run from the outside of the windscreen with the long end of the rivet protruding toward the center of the windscreen.
Repairing a broken roll bar windscreen tab - 986 Forum - The Community for Porsche Boxster & Cayman Owners
Run into the broken tab problem
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Suggestion
I just sit back and learn, but I did run into the broken tab problem.
Repairing a broken roll bar windscreen tab - 986 Forum - The Community for Porsche Boxster & Cayman Owners
Use bonded fastener
Suggestion or failed attempt
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Suggestion
If my bottom tab snaps, I'll drill out and use a bonded fastener from behind.
Repairing a broken roll bar windscreen tab - 986 Forum - The Community for Porsche Boxster & Cayman Owners
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Counts describe captured discussions, not unique people or a diagnosis. Author identities are not reliably stored. Exact duplicate evidence is counted once across matching discussions; one discussion counts at most once per action/state. Multiple repairs reported together remain a combination. Suggestions and failed attempts do not establish a fix. Matches cover whole discussions and can include related faults, model variants and incomplete threads.
16 eligible posts · 0 unverified posts · 1 discussions match the subject in their title or opening post.
986Forum: 1 discussions
0 evidence records excluded for query context · 0 excluded by outcome qualification · 0 adjusted by outcome qualification.
1 acknowledgements have no verified action link; they do not establish a repair result.
Like all roll bar windscreens mine are old enough to have lost most of their plastisizers. That means the release tabs become brittle and snap off if you're lunatic enough to try removing one to clean it. Don't panic, there is an easy and permanent repair. You will need a pop rivet gun, a small diameter pop rivet, a Dremel tool with a metal cutting disc a hacksaw blade and a drill/drill bit that matches the hole size needed for the pop rivet.
First take the broken windscreen and tab and measure out a length of hacksaw blade against it that will be the new spring to hold the tab in place. The length should be long enough to leave 1.5 times the pop rivet diameter back from the break in the plastic tab on each side. This is so the hole you will drill in the plastic windscreen and plastic tab will have adequate edge distance from the break in the plastic for structural integrity. I needed about 5/8 an inch of hacksaw blade to act as a "spring" to maintain this edge distance in the plastic.
Mark the length of hacksaw blade you think you need, and drill a hole appropriate for the pop rivet diameter and plastic edge distance into each end of the length of hacksaw blade.
After drilling, use the dremel tool to cut the hacksaw blade to length.
While holding the hacksaw blade in the proper place on the plastic windscreen, start match drilling a hole to mark its position. Remove the length of hacksaw blade and finish drilling. Check the length of the "spring" making sure its holes line up to about 1.5 rivet diameter on both side of the break in the windscreen/tab. If it's too short, make a longer spring
If it's good to go, place your spring on the inside diameter of the windscreen and pop rivet it in with the rivet gun. The rivet should run from the outside of the windscreen with the long end of the rivet protruding toward the center of the windscreen. Then drill and rivet the broken tab into place the same way.
That's it, you're done. - worked for me anyway!
Better yet, purchase nine8six kickass windscreen and gain an illuminum frame with aluminum clips, plus killer LED lighting on the windscreen.
Sorry to to hi-jack the thread, okay not really.
Pretty quickly dropped the idea of getting 3D models & CAM work, fixtures and all that's needed to get those clip done lol They would have cost a fortune once CNC'ed and anodized.
Can't compete with an item that now cost
$4.99
(see suncoast's website). Used to be so much more expansive at the time... hence where the idea of getting some made out of AL came from.
Seriously, remember paying $60 from a seller back in the days :/ Glad to see they are almost free now - about time
There's thinking outside of the box...very Rube Goldbergian.
It's not nearly as creative, but I just used zip ties on my friends 986. He was missing a tab on each mesh, so I figured zip ties would work best (they should be zip tied for security, anyway, so 2 problems solved with 1 zip tie
).
Hi all, new boxster owner here ('99 base). I just sit back and learn, but I did run into the broken tab problem. My solution is not for everyone, but if you work with epoxy, you can make new tabs. I taped up the roll bar with packing tape to protect it from my sloppiness, taped the screen to the roll bar, then built new tabs with epoxy fillet compound. Then I followed with an easy sanding fairing compound followed by black paint. If you're patient, you can get the tabs as nice as you like. Mine is about a one-foot job. LOL, looks good from one foot away. The two leftmost tabs in the photo were built from scratch. Also, I scored the plastic to get some tooth for the fillet compound.
Oh yeah, pictures are needed or it didn't happen. This is the top tab and cannot be seen unless the passenger seat is tilted forward and you look up at it from the back of the seat. This shot is a close up almost straight up from behind the seat. Since I can not see it, I didn't bother to hide, or even paint the pop rivets to hide them. For the lower tabs a bit of filing, epoxy and paint would go a long way towards hiding the repair. The reason I like this repair is that its a more robust solution than adhesive, at least any adhesives I'm familiar with. The spring action of the hacksaw blade also makes it easy to remove and install without breaking another tab.
Bummers... the price is going up again. Inflation stuff... goes up one day, down the other huh lol
https://www.****************************************************.com/product//986WSCLIP.html
^ that of course is ref to what was discussed later on your thread mate. Noting to do with the mesh tabs fix you kindly suggested. Apologies if this creates confusions
For a guy like yourself, I have millions mate. Even if I run out quick I'll do a one off just for you.
Keep up the tech ideas and contributions coming man, ref to other thread you've contributed. Clearly you know your stuff......
Your solution is far more robust than epoxy on plastic! Alas, I bought my boxster with the screen already broken and the small pieces were missing. If my bottom tab snaps, I'll drill out and use a bonded fastener from behind. Your rivets gave me that idea.
Hiding the blade with fairing putty or what have you, as you suggest, would be a much better way to go than starting new tabs from scratch.
I'm going to respond to this to tell my quick success story. I've had broken tab wind screens since I bought the car. Unlike James, I did not have the other piece of the tab so mine were pretty much useless. Had both bottom tabs but the top tab was gone. Hemmed and hawed on spending the coin to buy new ones until I found this thread.
Pretty simple repair and embarrassed I waited this long. Bought hack saw blades, rivets and a rivet gun. Had a rotary tool but honestly you don't need it. Broke off a piece of hacksaw blade, I did about two inches. Drilled a hole on the base l close to the back of the tab area. Did the same on one side of the blade. Used the rivet to put them together. Then bent the front half of the blade up enough to create a snug fit. Fed the bent part into the groove at the top of the roll bar then locked in the bottom tabs. Adjust as needed to ensure a tight fit. Better to have too much blade length so you can either break it off or cut it if needed. Mine now fit snug and arguably better than new. Will try to get some pics in a few days.
This is a source reference. Confirm exact model applicability in the original material.
