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Another rust combat

While my EFI conversion is making good progress and almost finished, my chassis needs more attention. The origin of the "brown pest" is 10 years back:

I bought the car in optically bad condition, lot of dents and paint damage, well used I would say, but almost none visible rust. A good base for my needs, as I wanted to build a nice toy, not a daily driver.

So I started to remove things I did not need anymore like heating, backseats, radio and all that stuff. The more I removed, the more I saw what has to be done else.

At a certain point I came to the conclusion, that I have to disassemble completely and remove all this protective material and the estimated four different paint coatings to check, what's underneath.

After a few shots removing that stubborn stuff, I searched for alternatives. Finally I decided on a base treatment. So I disassembled the car down to the raw chassis and stripped everything what had to come into the bathing. the big plus for this method is, that only rust will be gone, healthy metal stays untouched.

After the bath the whole story of the car was clearly visible:

To my suprice almost no rust, which was seen now as non existing metal, but a lot of accident signs all-around. I will post some pics later on this, have to scan them first from old photo-prints.

However, the body shop repaired some of the badest damages and after the car was primed with a 2K epoxy layer and painted as usual.

This was the birth of my rust problem: The painter did not painted the cavities or just let some paint fog (right word?) in. For my beginner eyes, the car looked nice like new at this time.

To make a long story short: I built-up the car and started driving.

After a few years (I drive only for fun on sunny days, made 10'000km within 10years) I observed some rusty water comming out of the rockers and tank support after washing the car

So I checked this and found raw areas almost in every cavaties, some had a little paint. As emergency procedure I made a body cavity treatment myself, because I did not found any serious shop here, who was able to do this seriously...

After a few visit at several body shops (from professional to feckless) I found one who will do this repair good and lasting for a long time For this, I have to disassemble the car again. So I take this chance and let him do some other work I wanted to do anyway in the future like closing the Sunroof opening, strengthen the weak areas etc..
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Roland

930 Turbo '81 Too many modifications to list
Old 10-14-2011, 03:37 AM
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Here are some pics from today:







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Roland

930 Turbo '81 Too many modifications to list
Old 10-14-2011, 03:49 AM
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As I said before, I take this issue to correct some other things I did not like or failed over the last then years like cracks from coil-overs and damages by the track use of my forerunner:

















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Roland

930 Turbo '81 Too many modifications to list
Old 10-14-2011, 03:50 AM
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Your car has lived a very hard life my friend....... the only real way to properly revive it, would be to strip it down to a complete bar chassis. I mean all the way down to bare metal.

Then properly repair/replace all affected areas, then repaint and then reassemble. However, you probably already know this.

There are products out there to treat the rust{RUST-MORT}, and stop it in it's tracks, but it does not repair the damage, really just another bandaid, but what are your expectations for life expectancy?

Mark

Last edited by full quack; 10-14-2011 at 07:24 AM..
Old 10-14-2011, 07:15 AM
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Yes, completly down-strip is what I do now. The chassis will be blasted where need is to repair/replace some sheetmetal. As you can see too, the back areas of the engine bay are quit deformated. This I want to fix too.

After discussion with my body shop guy, we will open the rockers etc. and see how it looks behind. Finally we will do what have to be done, so I can drive her for the next at least 20 years without body issues (fingers crossed)

As we talk about rust treatment, we will use Waxoil I think, heard good things about it and it's available here in Europe

I start next week and will update this thread once or twice a week, depends on time I can spend, not married and no children
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Roland

930 Turbo '81 Too many modifications to list
Old 10-14-2011, 08:10 AM
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The beginning

After a little time prepairing at home to store parts until refittment I started took today off and started with disassembly.

Here the last pic of the car before:



I started with stripping doors and then removed them:







Next was remove of the seats and harnesses:



And finally cage:

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Roland

930 Turbo '81 Too many modifications to list
Old 10-27-2011, 01:14 PM
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Hi Roland, looks you will have more work ahead of you.
Keep up the good work
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Trond R.
1979 930: Garret GT35r turbo, EFI, carerra intake, Link EMS, custom GT2 cams, 98mm JE P/C, 964 crank (stroker), custom valves & ported (XtremeCylinderHeads) etc..etc..
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Old 10-27-2011, 02:22 PM
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Only few progress today, front lights and rear quarter windows removed and one new "part" fitted





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Roland

930 Turbo '81 Too many modifications to list
Old 10-29-2011, 08:22 AM
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Got a little time today to go on

Remove Windshield, rear window and dashboard:





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Roland

930 Turbo '81 Too many modifications to list
Old 10-30-2011, 02:22 PM
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Gauges, panels and ventilation removed:



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Roland

930 Turbo '81 Too many modifications to list
Old 10-31-2011, 01:03 PM
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little progress

This weekend I removed Whaletail, front and rear bumper, backlights and at the end the Intercooler:





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Roland

930 Turbo '81 Too many modifications to list
Old 11-06-2011, 01:58 PM
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How far are you going to strip the car Roland?
Old 11-06-2011, 03:08 PM
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Quote:
Originally Posted by Jim2 View Post
How far are you going to strip the car Roland?
Jim

Totally
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Roland

930 Turbo '81 Too many modifications to list
Old 11-06-2011, 05:15 PM
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Fuel drained and tank removed

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Roland

930 Turbo '81 Too many modifications to list
Old 11-08-2011, 02:31 PM
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one more step

Engine is out, finally



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Roland

930 Turbo '81 Too many modifications to list
Old 12-05-2011, 01:10 PM
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I am a big fan of POR-15 as I own an Italian(the country where tin worms were born). You must follow the instructions and neutralize the surface before application but I have never seen it fail. My mechanic uses it on all the Italian's he services and swears by it.

This is a big job you are doing Roland, good work!
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Old 12-06-2011, 03:57 AM
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Steve

I know POR-15, a friend of mine uses too, good stuff I believe.

I won't do the sheet metal/paint work myself, a professional with experience on Porsche will do.

Don't know what product he uses for box sections etc. and what kind of treatment.

Unfortunatly I saw a few things I can do while I am there So it will take time until she's back on the track...
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Roland

930 Turbo '81 Too many modifications to list
Old 12-06-2011, 05:21 AM
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Very cool Roland. However, I didn't find this project in the 101 Projects book
Old 12-06-2011, 01:41 PM
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Quote:
Originally Posted by bleachii View Post
Very cool Roland. However, I didn't find this project in the 101 Projects book
You'll find in the Volume II
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Roland

930 Turbo '81 Too many modifications to list
Old 12-06-2011, 02:47 PM
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Update

Please see here for collateral issue:

Strange clutch issue

Thanks
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Roland

930 Turbo '81 Too many modifications to list
Old 12-11-2011, 03:58 AM
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