Project Outline and plan:

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Front Bumper Rust Repair and cutting into the custom race "nose" of the car to fit the front fenders.

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The Restoration Design panels have arrived! Initial fit of the rear quarters, and stripping off some of the race bits to make them work.

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Rear Panel Install Part 1!

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Rear Latch Panel Part 2!

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Final Quarter Panel Fitment, Passenger Side!

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Finished off with some weld thru primer today.

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You don't want to put plastic filler over the lead. So you'll either need to remove it with a torch or use lead filler.

Yea...that's what I was thinking too. Plus I want to learn lead filling...I think it's a lost art.

I just saw this car in person and it's the real deal although I don't envy the amount of work ahead.

And money.

But if it turns out to be close to the concept it will be a world class build.

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Thanks Milt. Nice seeing you IRL (we kept 6 feet apart).

I'm hoping because it's going to be mostly DIY that it won't be a tremendous amount of money. Famous last words.

:)

I've just uploaded the latest video of my 69 911S Blasphemy Build, where I try to figure out if I can use my flux core welder to patch some unseen body panels.

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Posted another video today wrapping up the fabrication and install of the passenger side kidney piece, and rocker panel patches.

I coated the inside with POR15 (thanks Zeke) and then finished it off with my signature pigeon poop welds.

First I used my propane torch to burn off the lead filler and give me something solid to weld on.

I made a couple of rust repair panels and was able to weld them on before grinding everything down and coating it with POR15.

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If you prefer the video...


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Today I tackled more chassis restoration, and I had to use a bottle jack to spread my rear frame rails! The full roll cage of this car had "compressed" the frame rails a few mm, and my replacement panel from Restoration Design was a good 1/2" off from being able to be installed.

This was the jack I eventually used, with a 2x4 against the opposite frame rail.

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I was able to use one of my regular floor jacks as a "proof of concept" and got the piece in for measurement.

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Quick test fit of the outer rear latch panel piece.
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After welding it on and cleaning up the welds.
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Then sealed up with a bit of POR15 as a stage 1.

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Am excited to get that rear panel on so I can finally fit the quarters.

If you want to see the video of this whole process, here it is:

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I'm just about to fully weld up my quarter panels and rear latch panel. I am borrowing a stock set of right and left bumpers to help dial in my alignment, but I'm curious what the general procedure is for ensuring panel gaps, especially around the doors, are spot on.

Here's where I am at the mo:

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My plan is to use lead filler where the factory did, but I'm most concerned, like I said, about panel gaps. What are the techniques to dial in my door gaps correctly?

Just uploaded a video on my quarter panel install!

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Great job Michael. Your perseverance is paying off. It's starting to look like a car again.

You need to hang doors before permanently welding outer sills(rockers) The whole shell fitment really revolves around door pillars.if you can get door fitting flush, this will help with rocker fitment.I once made error of fitting rockers (not 911) that sat so proud of door I had to cut them off and start again.Get the doors as close as you can then its shims, and hammers jammed in hinges.