Epoxy or welding to repair a cracked targa top frame?

[tmadden2]

My targa top went for a ride on the wind the other day and one of the corner pieces of the right lateral aluminum rib (911.565.030.46) cracked cleanly upon impact. These parts are apparently made from a potent mix of saffron, Fabergé eggs, and powdered unicorn horn. A replacement has proven impossible to source for under $1000, so I’m leaning towards trying to repair the break instead.

Option 1 is to disassemble the top, take the broken part(s) to an aluminum welding shop in town, and have them take a shot at it. Then get it all back together at home. My concern with this approach is that the top otherwise fits well and the process of disassembling and reassembling it could add some more problems around alignment and wind noise after the fact.

Option 2 is try to do everything in situ with a high quality aerospace epoxy such as Hysol 9394. My concern with this approach is that if the epoxy doesn’t take for some reason, it might be much harder to weld later after junking up an otherwise-clean break.

Any advice or other options you’ve got would be great. I always appreciate the knowledge that this forum’s members bring to these kinds of unique situations. Photos attached of the damaged area and the car during happier times.

- Tim

[john walker's workshop]

I probably have that piece. Right front, right? I have a stack of tops for parts.

[tmadden2]

Originally Posted by john walker's workshop

I probably have that piece. Right front, right? I have a stack of tops for parts.

Hi John -

It’s actually the long piece on the right side of the car, less the seals and other ancillary bits. I wish it was one of the little ones. It’s for a 1986 if that matters at all.

- Tim

[HarryD]

Dan Petchel is also a good source for these as well.

[RSTarga]

Send the top to Dan for repair.

[mepstein]

I would have it welded. Ask the welder if it can be repaired without disassembly. The guys who are good at their craft can work miracles.

[Biff]

Originally Posted by RSTarga

Send the top to Dan for repair.

+1


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[Biff]

It’s been a while since I owned a targa. Does this broken off ear have a lot of pressure? I’d J.B. Weld it first...give it a shot what do you have to lose? If it doesn’t hold then take it to a professional to weld and they should be able to tig it on both sides of the crack. Your going to have to get to both sides to have maximum strength when tig welding. Good luck!


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[Bob Kontak]

Originally Posted by RSTarga

Send the top to Dan for repair.

Dan is an interesting guy. I called him ten years ago when in Perth Amboy on a work trip and asked if I could come see his shop. Hung out for two hours. Saw his holding jig.

On the full rebuild of mine, he said you have a "this and a that" wrong part. Front clasps I believe, and he fitted it with the correct parts, no extra charge. The wrong parts went back into his used inventory, surely.

I suspect the bar replacement would be of little cost consequence. He has a stash of stuff. However, I cannot speak for Dan.

The top will be divine.

That said, what Biff says sounds like a viable option.

Also, John Walker could be your new best friend.

[47silver]

I do not think it is aluminum nor magnesium. Cant search now but do one and you will find the posts.

[john walker's workshop]

It's a pretty precision hinge so welding would be a lastt resort. Glue, defnitely not.

[MConn]

I went through this several years back. The roller-latch tops are harder to find since they only made them a few years. I contacted Dan - he is your best hope. I think the frame is magnesium. I ended up drilling and pinning my broken spot.



Mike

[tmadden2]

Originally Posted by 47silver

I do not think it is aluminum nor magnesium. Cant search now but do one and you will find the posts.

You weren't kidding. Apparently it's some kind of mystery alloy with a magnesium component. Thanks for the heads-up! I had no idea.

[illerucis]

Tim - did you ever find a resolution? The same exact thing happened to my Targa top last week. Tragic!

[Solamar]

Originally Posted by illerucis

Tim - did you ever find a resolution? The same exact thing happened to my Targa top last week. Tragic!

Finding a used part on Ebay, or John, Or Dan is your best bet. I'm a professional Tig welder and trying to weld that would be my last,last resort.

[tmadden2]

I sent the top to Dan. He replaced the broken arm, the skin, the headliner, the incorrectly-installed front locating pegs, and gave everything else a thorough tune-up. Money very well spent.

[illerucis]

Thanks guys - just called Targa Dan and he said it's a four-stage restoration. Since I'm 100% sure I bolted down the latch, it could be a latch failure on the top itself so I'll put in an insurance claim. Fingers crossed!