Great weekend: Clutch, bodywork, birthday fun

[Shaun @ Tru6]

My 84 has been pretty beat up over the years, hit twice in the rear (SUV women on cell phones didn't see me at stoplights) so when my 915 went a bit ago, I decided to tackle welding on a new rear lens panel while the motor was out. This was a great job, especially in that I learned how to weld sheet metal.

Some pics and tips:

here's what I started with already drilling out the spot welds of the old panel and removing it. You can see from one accident that the structural crossmember is dented, but since the decklid plunger panel was fine and everything else looked unstressed, I left it alone.


this was the bad corner where one of the trucks rode up the car slightly, sort monster truck rally style. Surprisingly, the quarter was pretty much fine.

Testing panel placement. I have already grinder/wire brushed the body member and coated with Wurth rust guard and then did my best bumping around the light bucket metal.


Then I realized to get "perfect" placement, you would need to mount the bumper. I ended up mounting bumper and lights after this pic.


Then it was time out for grandfather's 83rd and sister-in-law's (age closely kept secret) birthday party. Three 8 lb lobsters and steaks. What a great day!




8-year-old nephew being silly (water hose war followed dinner!!)


6-year-old nephew not to be outdone



Sunday below...

[Shaun @ Tru6]

Getting an early start, got the panel welded in. I drilled 1/4 inch holes in the panel, clamped in place and made nice little circles. LOVE the Miller 135. I used a 4.5/60 combo. Welds aren't beautiful, especially with some paint contamination, but they are plenty strong.


After tacking into the light housings and corner seams, I expoxied all visible seams. This system is a flexible expoxy similar to that used to bond on flares, etc.




Next I velcroed on the rear lens, one I picked up here on Pelican classifieds. All the nubs on the back side had been broken off, but 3 pieces of velcro and it should be fine in the short term. Long term I'll repair properly with nubs I pulled off my broken lens.


Finished after working on the decklid. Notice the line of silver/crease in the bottom of lid... someday I'll get that cleaned up with a little filler, probably when I paint this winter.

[Shaun @ Tru6]

Then it was time to focus on the clutch and get the motor back in. First, HUGE thanks to Chris Bennet for rebuilding my 915. Chris is easily one of the best guys ever.

Getting flywheel on after putting in new rear main seal.


Chris has by now come down from NH to help get the motor in.

Sachs power clutch. I found that installing with 2 studs, no lock washers made getting the rest easy to thread on, then go back and put lock washers on the first two.


One of those hi-torque, lightweight starters. heat? Who needs heat? I need to look into a solution for the starter being in the way of the exchanger hose.


Lots of work going on, no pics.


And were' done at 9PM, time for dinner.


car started and ran (a good thing) and the only thing I've got to do now is get the shift coupler on tonight and I'm good to go.

haven't driven the car in over a month... can't wait!!!

[Shaun @ Tru6]

Just realized I posted this in OT, sorry, can someone please move to Technical?

Thanks!