RUSTMAGEDDON - Bringing a 1969 911E Back From The Dead

[rennch]

I thought I’d keep you guys updated on this very rusty chassis project I’ve just taken on. I’m posting all of the videos to my YouTube channel of course, but I’m doing so many chassis reconstruction projects on this thing that I thought it would be worthy to post here as well.

This is a 1969 Porsche 911 E owned by a good friend of mine that has some sentimental value attached to it. He owns a lot of stock 911’s and wants to hot rod this one. It will probably end up with some sort of widebody flares, and a stance similar to my Grey Ghost build.

It looked a little rough when I sandblasted it, but then just got worse and worse, as I blasted more Bondo away:









Thankfully, almost every part is available from our host, or restoration design.

Gave it a coat of epoxy primer, and got it home on octossorie.






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[ADDvanced]

Nice, will follow on youtube too, love your fab skills. What's going to be the most challenging part for you, personally?

[rennch]

My first project was to reinforce the chassis since I’d be cutting off a lot of stuff. This will be a continual process of reinforcement as I move through the project.





I will be welding in a diagonal as well, but I need to have a bit of space to do the floors first. There are so many things that need to connect to the floors so I thought it would be a good place to start.

Yesterday I removed the driver side, outer and inner rocker and started cleaning that area up. Next I’m going to cut the rear of the floor pan out and get the replacement in place so I have some solid structure.








After a treatment of rust converter or two, I will POR15 in the inside of this space once I have all the replacement panels handy. Once I get the rear floor in with tech screws or Cleco’s, I will post a video on the Rennch YT channel. (rennch.com/YouTube)

[Bill Douglas]

Good skills there Michael.

[2.7RS]

Let me guess.

California car all its life.
Never driven in the rain
Always garaged

Good luck !

[rennch]

I think the thing was just hanging out in 2 feet of water for a couple years. :P

Originally Posted by 2.7RS

Let me guess.

California car all its life.
Never driven in the rain
Always garaged

Good luck !

[Showdown]

Ship of Theseus?

My god is your friend lucky to know you.

I will eagerly await the new videos; they’re entertaining, informative and well produced.

[rennch]

Originally Posted by Showdown

they’re entertaining, informative and well produced.

That is a huge compliment. Thank you.

[rennch]

Nice progress today. I’ve got about eight hours into it so far. I completely removed the driver side, inner and outer rocker, and the rear half of the floor pan. The replacement pan I have is not from restoration design… In fact, I have no idea where it’s from and it could use a little bit of help, but it’s nice to see some clean metal on there.






Out with the old, in with the new!



That’s it for now. It needs a ton of fitment work to get anywhere close to being possible but it really is nice to see some fresh metal on there.

[rennch]

Made some progress on the drivers side rocker and the rear floor in this one.

https://youtu.be/YTta0a0aBEY

[PeteKz]

I look at some of the rust bucket projects some of you take on, and I think, "I am not worthy!"

I would just start with a better tub, preferably a unicorn with "no rust." Seriously, I gotta wonder why you would start with this. Is the sentimental value that great?

[Marine Blue]

I’m curious what the assembled 911 looked like before you uncovered it to expose that rust! I can’t help but wonder if the chassis actually maintained any type of rigidity in a corner.

I look forward to seeing the progress on this….

[rennch]

It actually looked like a halfway decent car. I blasted so much Bondo off of it.


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[rennch]

Originally Posted by PeteKz

I look at some of the rust bucket projects some of you take on, and I think, "I am not worthy!"

I would just start with a better tub, preferably a unicorn with "no rust." Seriously, I gotta wonder why you would start with this. Is the sentimental value that great?

These cars are really cool, and they are forever “in style“. Why not bring them back if someone has the means?


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[Mike Andrew]

Michael;

Rough guess how many hours will be in this before it is ready for primer/paint?

Hell of a job. Looking forward to seeing it incrementally resurrected.

[Kemo]

subscribed! thanks for posting...love these type of projects.

[rennch]

Originally Posted by Mike Andrew

Michael;

Rough guess how many hours will be in this before it is ready for primer/paint?

Hell of a job. Looking forward to seeing it incrementally resurrected.

Not sure. Maybe 250-300?

[emac911]

Originally Posted by rennch

It actually looked like a halfway decent car. I blasted so much Bondo off of it.


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I know that feeling....I call sandblasting the truth serum.

Amazing what some people can accomplish with a gallon of body filler and chicken wire!

[rennch]

Originally Posted by emac911

I know that feeling....I call sandblasting the truth serum.

Amazing what some people can accomplish with a gallon of body filler and chicken wire!

You aren't wrong there!

[blucille]

don't forget expanding foam. I had a car that the suspension pan and rockers will filled with expanding foam, covered in bondo and painted by the previous owner. Good thing cars were cheap back then....