911 front suspension pan rust

[Collette]

I am replacing my 1977 911 front suspension pan as well as a few other components I’ve found during removal.





I’ve built a jig to reference the position of the passenger side suspension pan studs. (The drivers side and rusted out and had pulled away from the rest of the car).



Fortunately I had a borescope camera and found that rust had made its way back under the left lateral support all the way to the steering hump.




After removing the surface rust with a wire wheel i found that the metal was thin and pitted. I didn’t want to try and weld to eroded thin metal so I bought a new inner fender piece for the front and rear sections hoping that I can fab the center few inch section to connect them.

I also build a reference jig for the steering rack Mount because there were pinholes above that on the rear side of the front suspension pan pocket.



I found rust on the top side of the steering rack mount skirt so I removed that as well.





I’m posting this to see if there are anyone that knows of a replacement part for the rear driver side pocket where the rust bled onto the suspension pan. I already have the front portion and don’t want purchase the full piece just for that pocket. I’m also not opposed to making it but it would take some serious bending to get that pocket just right.

I’d also like to find good dimensions to make sure the driver side suspension pan studs are where they should be.

Thanks for looking.

[Uwon]

Following......

[Carl S.]

Nice, What are your going to use to get the new pan at the correct height? Your jig should keep the left and right plus front and rear in position.

I have to do the same except both of my front mounts are gone.

[Collette]

Originally Posted by Carl S.

Nice, What are your going to use to get the new pan at the correct height? Your jig should keep the left and right plus front and rear in position.

I have to do the same except both of my front mounts are gone.

I’m not totally sure on how to check height especially since the car isn’t on a level surface. That’s one of my biggest questions. I think stoddard has a stud placement jig but I can’t justify using it just once.

If anyone has ideas on this it would be appreciated.

[Carl S.]

I bought a jig for just this purpose. It was from another member on here i believe.
My plan was to build my own frame bench out of 4x4 square tubing. level the bench, weld up some brackets to hold up the car at level. I could then go from zero plane and shoot it with a laser lever to get the correct placement. All vertical measurements are off of the zero plane.

I could build the frame for under $300, but I have a lot more to replace.

[Collette]

That sounds like a solid plan. My only problem is I don’t want to drop the engine because that’s already been restored and runs well.

If the jig mounts to the steering rack mounts and pedal area bearing brackets then that should project out height, right?

[Carl S.]

I would think so, but I have not used one yet. I don't know how true it would project out from the rear mounts. Might be just fine but there again, I have no basis to go on.

Perhaps someone who has used one can offer some assistance.

My car will be a shell so it would be easier to mount on the bench.
I thought that in my case, between using the frame bench and suspension jig I should be able to get really close to factory specs.

[Carl S.]

Where are you located?

[Collette]

Originally Posted by Carl S.

Where are you located?

Kansas City

[Collette]

Finishing the pie shaped piece later and then cutting out the steering rack mount taper pin hole.

[Jonny042]

I used a self leveling laser level to confirm the position of everything before final welding. The bottom of the door apertures are horizontal and you can work from there, there are dimensioned drawings available that you can use.

Not as easy or fast as using a Celette bench, but right is right, no matter how you get there.

Keep up the great work and thanks for sharing!!!

[Collette]

Originally Posted by Jonny042

I used a self leveling laser level to confirm the position of everything before final welding. The bottom of the door apertures are horizontal and you can work from there, there are dimensioned drawings available that you can use.

Not as easy or fast as using a Celette bench, but right is right, no matter how you get there.

Keep up the great work and thanks for sharing!!!

Thanks!

Do you have pictures of where you use the laser?

Also, any good sources on dimensions? Everyone says restoration design has them under one of the tabs. I found the tab but they only have “PET” diagrams.

[Jonny042]

Originally Posted by Collette

Thanks!

Do you have pictures of where you use the laser?

Also, any good sources on dimensions? Everyone says restoration design has them under one of the tabs. I found the tab but they only have “PET” diagrams.

You can check the earlier pages of my build thread:

Project Heavy Metal - an all steel classic, remastered

In the search you might find the drawings. If you can't find anything PM me your email address I might have them saved.

[Jonny042]

PS they are often referred to as "check dimensions":

Building fixtures like Celette for my bench, need 911-930 factory dimensions and pics

[Jonny042]

Here are a few, I can email them and more:

(Hint - "Datum 0" and Plan 0 are the same, and you can find the location on the drawings if you are careful, or there's a pic in my build thread.

[Carl S.]

Way to go, I will be doing the same at some point. Mine was in an accident at some point. I think I need to go a step further with some type of home made Celette bench. Nice Job.

[Flojo]

Originally Posted by Jonny042

nice.
is there a data file (3-4gb?) large enough to make a poster print 50x70cm ?

[Jonny042]

Originally Posted by Flojo

nice.
is there a data file (3-4gb?) large enough to make a poster print 50x70cm ?

I believe these are fold-out pages from the earliest service manuals. A good scanner could make a high-res file but the original is probably not all that sharp.

[Collette]

Originally Posted by Jonny042

PS they are often referred to as "check dimensions":

Building fixtures like Celette for my bench, need 911-930 factory dimensions and pics

Great!

Thanks for sharing all this info Jonny. There’s a few drawings here that I haven’t seen and will definitely help.

[David Inc.]

Can I ask if there were any noises while driving prior to opening the pan up for inspection?

I've had a clicking noise from my front end that I have had no luck identifying even with all new stuff and I worry that it's the sheet metal giving way...