Hotrod Build Project Video Series - Longhood Backdate <$250

[tperazzo]

I've been working on changing the look of my 1974 911 and making it lightweight. Although I'm sticking with steel fenders and hood, the fiberglass bumper offers a big weight savings.

I fabricated all the metal brackets and extension pieces to convert the short hood parts to longhood stuff. Instead of buying new parts I invested my time to make everything myself making this a true budget build. Less than $250 including the parts!
Please check out my YouTube channel for weekly updates:
https://www.youtube.com/user/tperazzo?sub_confirmation=1

[75 911s]

Keep up the great work. You've got amazing skills with metal. I was really impressed with the fender pieces that you created.

I was surprised at the small nylon hammer used for the hood extension piece. I guess because that curve is so drastic, you need a small hammer to get into the curve. I was wondering why you didn't just roll it on the english wheel to the profile you needed and then use your templates to gauge the profile?

Where did you learn your metal skills? Do you have some other car projects with metal work we can see?

[tperazzo]

Hi Duane,
Thanks for the kind words, but I'm just a regular amateur dude. The reason why I used the hammer is because I'm not skilled enough to shape it with the English wheel only. Maybe with some practice I could do it, but this was literally my first project with the English wheel and it isn't even my wheel. The hammer created the compound shape and I just smoothed it out with the wheel, which was really satisfying by the way. Next week I will make the inner panel using the same method, so I'll bring my camera hopefully.
I do have a lot of experience with the TIG welder and patching panels that were pre-made. In my experience all those aftermarket and even original panels always need to be messed with to fit well. That is why if I can make it myself I'm usually ahead of the game in the end, plus I enjoy the challenge.
I do have another project that I'm creating a video introduction for. So you will have to wait a bit for the reveal, but I think you like it.
Cheers,
Tom

[tperazzo]

This week I dance with an English Wheel and perform metal fab at the beach. The inner skin and outer skin are complete on this Porsche 911 longhood backdate conversion.

Here's the link to the video, please subscribe to the channel if you like it.
https://youtu.be/b9PtEoh8xoA
Thanks,
Tom

[tperazzo]

Short hood to long hood backdate almost complete. I still need to add the seals and align the turn signals.



I'm happy with the strength of the inner latch panel extension.



This shiny extension was tig welded on.



Watch the latest video here:
https://youtu.be/GkpAp_jls0E

[tperazzo]

It was a bit tricky to get the bumper to body seals installed on this backdate, but in true hotrod fashion this is what I came up with. I made this closeout panel and curly-Q retainer channel to captivate the seal. I also made seal channels for the fender seals to keep them in place for good.







Testing the seal contact.




Here's a link to the youtube video

[tperazzo]

This week I caught my Porsche on fire and struggled getting the rear fiberglass bumper to fit. I'm not sure who made this bumper or what it came from as I bought it used.




You can watch all the drama here in the youtube video link below:

[tperazzo]

After the reflector panel was removed the corners needed some metalwork to blend into the backdated license plate panel.

I used lead here like the factory did to recontour the shape after a little bit of welding and grinding of course.





If you want to watch the video on youtube, here's the link:



Cheers,
Tom

[tperazzo]

This week I modified and installed an OEM license plate panel on my backdate project.

I decided to try a hybrid bumper approach where the center is steel and the sides are fiberglass. This allows me the best chance to align everything well and keep the costs down. An added benefit is the steel panel is actually lighter than the Fiberglass one.

I plan to make my own custom bumperettes sometime soon.





Here's the video link:

[Hi_Fi_Guy]

Thanks for sharing your progress.

[75 911s]

Good plan to put the extra work into the bumper. Can't wait to see the bumperettes!

[tperazzo]

Thanks guys for the words of encouragement! This week I started the custom bumperettes. They are Singer-ish, but a will be a bit narrower! They will be filled in, so the picture below is work in progress. Thanks for watching.

Tom

Link to video

[TheMetalSurgeon]

great job! nice job on the video's too.

[tperazzo]

Originally Posted by TheMetalSurgeon

great job! nice job on the video's too.

Thanks Jon! I've seen your metal work on other forums and its fantastic. Means alot to me.

[mrm930]

good for you - lead work is the only way to go

[tperazzo]

I managed to finish both of my custom DIY bumperettes this week. This rear bumper ended up being a lot more complex than just slapping on a fiberglass cover. I wanted a better fit, retain some of the OEM features that work, and customize it a bit.

I had fun making these Aluminum bumper things starting with paper templates, Cutting flat sheet with the CNC, hand forming the radii, welding the box section, and smoothing it out.

Yes, they look like Singer's and I tried a few different shapes but I like this best. Mine are definitely narrower than the Singer ones.

I plan to at least polish and maybe chrome plate. The bare aluminum won't stay shiny for long.



Here's the link to the to youtube video if you want to see all the DIY steps.


Cheers,
Tom

[tperazzo]

Time to take a break from the rear bumpers and work on the rear flares for a change.

Because I'm cheap, I didn't order the reproduction RS flares. Instead I bought an SC flare one ebay for cheap, $50.

Then I found this great Pelican thread on the difference between the SC and RS flare.
https://forums.pelicanparts.com/porsche-911-technical-forum/370218-rs-vs-sc-flares.html

It was determined by others and confirmed by myself that material needs to be added to the wheel arch where the lip goes inboard. The upper arch remains unchanged. The total height of the edge profile is 28mm at its tallest point.

So here's the result of my modified SC flare to look like an RS flare.



All the research and methods used are shown in the my weekly youtube videos. The video below shows how I estimated the profile dimension using photoshop and known reference dimensions.



Thank you,
Tom

[tperazzo]

Got my faux RS flare aligned, trimmed, and tacked in place now for its final TIG welding procedure.

I used a bar through the quarter windows to reference the flare position to make sure I welded it in the correct spot. So far so good.

Some stretching of the existing body was needed to get the contours to line up, but nothing too significant.


Here's the link to this weeks video. The final welding video will be out this Saturday.


Thanks for watching!

[tperazzo]

This week, I fully welded in the passenger flare. Its about five feet of TIG welding and metal finishing. Plus I had to massage the existing torsion bar hole because the person who cut the flare off destroyed the area.

I also gave a quick discussion why I chose to TIG weld this versus MIG weld. Its no surprise I'm a huge fan of TIG because its possible to get a smoother metal finish requiring less filler.

Here's a shot of the finished and smoothed install.



Here's the video

[75 911s]

Hey Tom

What wheel tire combo are you planning on running? I imagine a 8 or 9" Fuchs right? What tire?

I realize you are making an RS flare, therefore the typical RS specs would be your goal. What about getting tires and wheels in there to help make sure everything is fitted right? I mean I know the wheel moves around a lot due to alignment and you can always use spacers etc, I just wonder if that would have helped the process at all. I don't speak from experience, other than watching other builds and trying to get my own fitment perfect, but rather I speak from curiosity. Keep up the great work.