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Registered User
Join Date: Apr 2003
Location: Tampa FL
Posts: 798
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Shiny new front pan
I am getting ready to rebuild my complete suspension but before I do I needed to replace my front suspension pan. I had some pretty good battery corosion and what I thought was a "little" rust. As you already know there is no such thing as a little rust....
Once I got the battery tray out I realized that the PVC undercoating can hide alot of problems. Overall it wasn't bad. I drilled out all the spot welds except for the bottom seams which I used a grinder to cut out the spot welds. I removed all parts that were rusted and cleaned off all areas where I would weld. Then I dry fit the piece and measured bolt holes about 40 times to make sure it was in the exactly correct position. I then tacked it in place and double checked my measurements before I welded the new pan in place. (Don't laugh at my welds, I suck at welding ![]() I coated the whole thing in POR15 and will clean it back off in the areas I plan to weld ih the batt tray. I also plan to spray a rubberized 3M undercoat on after it is all over. ![]() ![]() ![]() ![]() ![]() ![]() ![]() Pat |
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Licensed User
Join Date: Feb 2003
Location: ....down Highway 61
Posts: 6,485
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Pat, that looks great. Nice job! Way better than mine!
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Very nice bro, now you gots to get it back together...again...
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Matt '82 911SC Targa! |
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pat S! that is nice! i think your welds came out pretty good.
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poof! gone |
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Registered User
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Location: Tampa FL
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Thanks guys,
I forgot to add the three things I'd do different next time: 1-Wear ear protection. Not due to sound, but because I was grinding in several diferent postions. And at one point a hot spark bounced of something and straight into my ear. Man that SUCKS! 2-Follow instructions and drain the gas tank. I kind of forgot that there are two hoses at the base of the tank. When I started lifting it out with about 1/8-1/4 tank of gas I started hearing the sound of running water, or in this case gas. Lost about 4 gallons on the floor before I was able to get the situation under control... Luckily, nothing happened. 3-I'd cut the pan out along the seam that runs under the car and along both sides. by the time I cut out all the spot welds, there wasn't much metal left. If I ever do it again, I'll just cut the pan along the seam then grind down the lip to the thickness it should be.
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Current: 07 S4 Avant, 06 Volvo S60R Sold: '74 911, 01 986, 93 Volvo 240 |
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glory at last! GLORY AT LAST!!!!
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1979 911 SC Targa http://www.pelicanparts.com/gallery/Mike_Kast |
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Awesome job, I like the picture of the old parts compared to the new parts. Rust is definately an enemy but looks like you won the battle.
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John Adams 1980 ROW 911SC |
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You might consider the Porsche undercoating material. I used both under my car (3M rubberized and the Porsche brand) and the Porsche stuff matched the underside of the car much better.
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Vance '83 SC Cabriolet - The "Matrix" '73 914 - "Spicy Mustard" - SOLD |
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Location: Long Beach CA, the sewer by the sea.
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My FB page: www.facebook.com/oddjobfix Antique and Collectibles Repair and Restoration On YouTube at "oddjobfix" |
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Sounds good, Thanks guys!
Milt, let me know what you find please. Pat
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Current: 07 S4 Avant, 06 Volvo S60R Sold: '74 911, 01 986, 93 Volvo 240 |
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17 years and 17k posts...
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Pat,
Nice looking work!!! Thanks for sharing your "lessons learned"!
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Art Zasadny 1974 Porsche 911 Targa "Helga" (Sold, back home in Germany) Driving Ford company cars now... www.ford.com |
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Join Date: Apr 2003
Location: Tampa FL
Posts: 798
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Okay, Lesson learned #4 - Metal Fume Fever (Zinc Fever) SUCKS more than a spark in the ear!
I had an old 3M respirator, was welding the panel on a 74 chassis, but did it in a closed garage. (Yeah, well, hindsight is always 20/20 and it's cold out you know.) Well since none of the metal is galvanized I wasn't too worried even though the filters in the respirator needed to be replaced. But today I got hit with a very bad feeling. Around 1pm (17 hours after I finished welding) I started getting a headache. I didn't think much of it, but then by 6pm today I also got very nauseated, heat flashes/cold chills, fever, and a very strong metal taste in my mouth. Now at about 10pm I'm feeling much better but still have all the symptoms. Strange though.... I figured this would happen shortly after welding, not nearly a full day later.... From the OSHA web site: Quote:
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Current: 07 S4 Avant, 06 Volvo S60R Sold: '74 911, 01 986, 93 Volvo 240 |
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that is weird man!
I find it harder to take care of myself when I'm working in my garage than when I'm at work. I think it's because I get relaxed and take my time more. I hang out and putter where at work i'm totally on, So I don't always remember to wear the mask when I should be wearing it. That zinc thing sounds nasty!
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1979 911 SC Targa http://www.pelicanparts.com/gallery/Mike_Kast |
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Pat S! whoa, that zinc topic should be another thread! i think you need to match the correct filter to the task. most of us only have the pink hepa filter, and i dont think that filters the zinc vapors or the lead in that type of work. hope your feel better soon. thanks for the heads up.
cliff
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Pat, that looks great. I especially like the tow-hook relocation. I have pretty mediocre welding skills, do you think I can unweld the one in the stock location and add one like yours? My cars front end went over a curb (I was driving like an idiot in a residential area) and the tow hook got completely bent over, but neither one of the tires came in contact so the suspension geometry is still alright. What kind of metal did you use for that?
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Amir '83 911SC |
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Somewhere in the Midwest
Join Date: Oct 2001
Location: In the barn!
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huh!...
"The subject can then appear to be more susceptible to the onset of this condition on Mondays or on weekdays following a holiday than they are on other days." Did you add that Pat? Nice work by the way! |
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Quote:
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1979 911 SC Targa http://www.pelicanparts.com/gallery/Mike_Kast |
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Somewhere in the Midwest
Join Date: Oct 2001
Location: In the barn!
Posts: 12,498
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Crap...I should use that one on my bosses! I won't have to go in on Mondays and days after drubnken holidays.....
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Registered User
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Quote:
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The only good thing about the metal fever is that it goes away quick. If you can imaging compressing a normal 48 hrs worth of flu into about 5 hours that really was how it felt for me. I'd guess that the more exposure you have the longer it would last, but I'm not really sure. Overall still another interesting learning experience. |
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