Painting a 944 – 2.5L NA

Overview

This guide outlines the process for properly painting a Porsche 944 (8-valve engine variants) to achieve professional results. A high-quality paint job enhances the car’s appearance and protects its body, but it requires meticulous preparation, including removing specific parts, sanding, priming, and leveling the surfaces. The procedure is tailored for the 1983–1985.5 (pre-85.5) and 1985.5–1988 (85.5 onwards) variants, with distinctions noted where applicable. Expect a quality paint job to cost $2500–$4000, depending on location and labor rates.

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Tools Required

• 10mm (3/8 inch) wrench
• 13mm (1/2 inch) wrench
• Phillips and flathead screwdrivers
• Sanding tools (orbital sander, sandpaper in various grits)
• Priming and painting equipment (spray guns, compressor)
• Blocking tools (sanding blocks, guide coat)
• Masking tape and paper

Parts Required

• Primer (two colors for blocking)
• Automotive paint (color of choice)
• Clear coat (optional, for added protection)

Step-by-Step Procedure

Step 1: Remove Front Components

1. (Pre-85.5) Remove the nose panel if it’s removable. Early 944s (1983–1985.5) may have non-removable nose panels, which must be painted on the car. Use a 10mm (3/8 inch) wrench to loosen bolts securing the panel.
2. (85.5 Onwards) Remove the nose panel, which is always removable on 1985.5–1988 models. Use a 10mm (3/8 inch) wrench for the bolts.
3. Remove the headlight covers using a Phillips screwdriver to access and unscrew the mounting screws.
4. Remove the front spoiler and front bumper. Use a 13mm (1/2 inch) wrench to loosen the bolts securing the bumper and spoiler to the chassis.
5. Detach the lights (parking lights, turn signals) and bumper pads from the front bumper. Use a Phillips screwdriver for the light assemblies and a 10mm (3/8 inch) wrench for the bumper pads.
6. Remove the side marker lights by unscrewing them with a Phillips screwdriver.

Step 2: Remove Side and Roof Components

7. Remove the side mirrors using a 10mm (3/8 inch) wrench to loosen the mounting bolts inside the door panel.
8. Remove the door handles. Use a Phillips screwdriver to access the screws behind the handle trim.
9. Remove the roof trim pieces by carefully prying them off with a flathead screwdriver, ensuring not to damage the clips.
10. Remove the sunroof and its seals. Use a 10mm (3/8 inch) wrench to loosen the bolts securing the sunroof assembly, then carefully lift it off and remove the rubber seals.

Step 3: Remove Rear Components

11. Remove the rear hatch by disconnecting the struts and using a 13mm (1/2 inch) wrench to loosen the hinge bolts.
12. Remove the tail lights using a Phillips screwdriver to access the mounting screws behind the light assemblies.
13. Remove the license plate assembly by unscrewing it with a Phillips screwdriver.
14. Remove the rear bumper cover and ground effects. Use a 13mm (1/2 inch) wrench to loosen the bolts securing the bumper cover to the chassis.
15. Remove the rear side marker lights using a Phillips screwdriver.

Step 4: Prepare Surfaces for Painting

16. Sand the car body and all removed parts (e.g., bumper, sunroof, nose panel) using an orbital sander with progressively finer grits of sandpaper (e.g., 120, 220, 400).
17. Repair any dents or dings using body filler, then sand smooth to ensure a level surface.
18. Apply a base coat of primer to the car and all removed parts, following the manufacturer’s instructions for drying times.
19. Perform blocking to ensure a smooth painting surface. Apply a second coat of primer in a different color (e.g., gray over white). Hand-sand the surface with fine-grit sandpaper (e.g., 600). As the top primer color is sanded, the base color will show through unevenly if the surface isn’t level.
20. Level any uneven areas identified during blocking by applying additional filler or primer, then sand smooth.

Step 5: Paint the Car and Components

21. Mask off areas not to be painted (e.g., windows, remaining seals) using masking tape and paper.
22. Apply automotive paint to the car body and all removed parts using a spray gun, following the paint manufacturer’s instructions for coats and drying times. Ensure even coverage.
23. (Optional) Apply a clear coat for added protection, following the manufacturer’s instructions.
24. Allow all painted surfaces to dry completely, typically 24–48 hours, depending on the paint and environmental conditions.

Step 6: Reassemble the Car

25. Reinstall the rear side marker lights, license plate assembly, tail lights, rear bumper cover, and ground effects, reversing the removal steps. Tighten bolts to 20 Nm (15 ft-lbs) for bumper and hatch components.
26. Reinstall the sunroof and its seals, tightening bolts to 10 Nm (7.4 ft-lbs).
27. Reinstall the roof trim pieces, door handles, and side mirrors, tightening bolts to 10 Nm (7.4 ft-lbs) for mirrors and handles.
28. Reinstall the front side marker lights, lights, bumper pads, front spoiler, and front bumper, tightening bolts to 20 Nm (15 ft-lbs) for bumper components.
29. (Pre-85.5) Reinstall the nose panel if it was removable, tightening bolts to 10 Nm (7.4 ft-lbs). If non-removable, skip this step.
30. (85.5 Onwards) Reinstall the nose panel, tightening bolts to 10 Nm (7.4 ft-lbs).
31. Reinstall the headlight covers, tightening screws securely with a Phillips screwdriver.

Post Procedure Checklist

• Inspect all painted surfaces for even coverage, with no runs, drips, or uneven areas.
• Verify all reinstalled components (e.g., bumper, sunroof, mirrors) are securely fastened and aligned properly.
• Check for any paint overspray on non-painted areas (e.g., windows, seals) and clean if necessary.
• Ensure the sunroof operates smoothly and its seals are properly seated to prevent leaks.
• Test all lights (headlights, tail lights, side markers) to confirm they function correctly.

Sources

• Clark’s Garage
• Pelican Parts
• Porsche 944 Workshop Manual, Volume 1
• YouTube