Another chunk of steel welded in!

[DarrylD]

I'm moving my way down the left rocker. Here's a healthy chunk of '68 Porsche steel welded into my rusty '66.



I'm also test-fitting new rockerpanel pressings, compared to cutting out clips and welding them in, new replacement sheetmetal is a snap!

I'm making a little progress every day I work on it! http://members.aol.com/darryld/912.htm

[Zeke]

Originally posted by DarrylD


I'm also test-fitting new rockerpanel pressings, compared to cutting out clips and welding them in, new replacement sheetmetal is a snap!

You got that right! I know I say this every time, but......OUTSTANDING! You set the bar high, man.

[304065]

Darryl, I gotta tell you, your documentation of this process is outstanding. This is a magnificent trail of bread crumbs you are leaving for us.

Also, when I read about how you intend to keep the original recessed engine cover release I about cheered out loud. Bravo, man, for keeping the faith.

[jpnovak]

Fantastic work! btw I like how I can see the shifter through the hole in that picture. I wonder what section of sheetmeal fits there?

[Zeke]

Originally posted by jpnovak
Fantastic work! btw I like how I can see the shifter through the hole in that picture. I wonder what section of sheetmeal fits there?

That's too funny. I didn't even notice the silhouette of the shifter and the e-brake and the prints on the wall beyond. For those that never unbolted the front fender, that's base of the A pillar that Darryl is replacing. There's a similar one at the base of the lock (or strike panel) and they both catch water and dirt like a bowl.

What were they thinking ???

[Rich76_911s]

WOW, what amazing work. I love your website and will be referencing it frequently. I hope someday I can do work as nice as that, or do you wanna come visit me for a couple weeks?

Rich

[rick-l]

DarrylD, I wonder what is on your site that my local Big Brother won't let me look at it? I get this message;

Access Denied IT has instituted virus filtering on our inbound forward proxy servers

I can get to all the other porn sites

[DarrylD]

Wow, I'm glad you guys enjoy watching my progress and I greatly appreciate the positive feedback! Compared to some of the work I see other Pelicanheads doing with rotisseries and stripping the entire shell to bare metal, etc., I think my restoration work is really just doing a bunch of patchwork like fixing battle damage to keep an old warbird on the flightline. When I get done I would like the car to look like a well maintained original not a brand new car.

My restoration journal documentation "hobby" started about the time I got my first digital camera and my 70-something Dad, who lives in Colorado, got a computer with Internet access. I was restoring my WWII jeep at the time and he loved to keep-up on what I'm up to and how my skills were progressing.



This is one of my favorite photos of my Dad and me. I grew-up a "shop rat" hanging out at my Dad's bodyshop as a kid. He pretty much taught me everything I know about autobody work by example. He also taught me woodworking and I've done quite a bit of cabinet building, a skill which really comes in handy when doing any task requiring careful measurement and cutting.

Anyway, my Dad, who is now 83, and I discuss my restoration journal progress via phone and e-mail just about everyday. I love sharing that information with him and anybody else who cares to read it.

Oh, and the shifter and parking brake handle are visible in the photo because I've already cut the floor out all the way to the pedals on the drivers side of the car.

[Rich76_911s]

Since some of the best body work guys are on here. I've got a small collection of rusty 911's that need a lot of fix'n. So how do you start to learn about body work, rust repair, ect ect. I am thinking of having a pro fix the worst areas of the 1980SC, the inner fenders. But the '76 I want that to be my project and fix that all myself in time, A LOT OF TIME. Is there a book you would suggest to start with or what? Unfortunetly my dad doesn't run a bodyshop, although with his garage loading up with his and my rust buckets maybe we should consider it.

BTW, that is a great Photo of you and your Dad.


Rich

[DW SD]

WOW! Amazing work! Just curious, why do you use the Eastwood encapsulator and then the SEM product? Would you recommend one over the other? I'm doing a bit of "rust prevention" myself and would love your opinion. I have some very light surface rust where some old undercoating was not well applied.

Thank you,

Doug

[DarrylD]

Hey Rich! There are a bunch of great books and videos on autobody repair skills available from Eastwoods (http://www.eastwoodco.com). In my mind, the biggest skill to master is welding which is really less a matter of study and more one of practice. My skills get rusty between projects so I usually start my welding work on the least visible parts of the car and save the critical stuff for later when I've gotten "the touch" back.

Hey Doug! I usually use the SEM Rust Seal on places I strip and wire brush and there's still some visible rust in the pits, probably more as a matter of habit. I like the SEM Rust Seal because you can quickly wire brush thru the sealing layer for later welds and such. I use the Eastwoods Rust Encapsulator instead of primer on areas that have light surface rust. The only place I've used both SEM and Eastwoods Rust Encapsulator on this car is when I spot-welded the new steel patch over the front suspension box section, on to old rust pitted steel sealed with the SEM and then used the Eastwoods product to seep into the spotweld seam to keep future moisture out. I put a coat of Wurth high-build underseal over all that as an extra measure of sealing the surface. It's probably overkill but I sleep better knowing I've taken the extra steps.

[911pcars]

Hey Darryl,
Can you eyeball the thickness of the replacement rocker and let me know? Doing some research. A micrometer reading will do as well. :-)

Good luck on your project (There's less luck and more skill as we know). Good job.

Thanks,
Sherwood

[DW SD]

Thank you for the information!
I read through your complete project - really is amazing the amount of work going into it!
Thanks again!

Doug

[Classic]

Darryl,

Great work mate i'm just now getting to the rockers on my 69 any pitfalls to watch out for?

[DarrylD]

Hey Doug! I try not to think of how much time I've invested... what you're witnessing is the harnessing of the power of Obsessive-Compuslive Disorder! You like this, you should see the wonders I can do with denial!

Hey Sherwood! Inners - Restoration Design, 0.059" or 16 gauge; Outers - Dansk, 0.046" or 18 gauge

Hey Classic! Take a close look at the inside longitudinal panel, the one the seat rail is bolted to. If that panel is rotten beyond reuse, you're in for big trouble. A little rot at the floor sheetmetal flange is not beyond patching but beyond that, I'd look at grafting in a nice post '76 zinc-dipped clip from the window pillars down!

[Classic]

yeah i've got the outer and inner off one side and everything looks good, when i stripped the floor back i didn't find any rust.

It's the usual story with my rockers bog and tin rivited over the sill.

I'm following your longitudinal work with interest, as at some point in my cars life someone jacked it up and chipped the SKS off and rust has taken over.

[Classic]

one of the interior finished



If the PO had redone the SKS once in the 35 years i don't think i'd have these issues.

I'm approaching my rebuild the same as your self patch and paint, i wish i had your body working skills, but i'm getting better.

[Bobboloo]

Keep the posts coming Darryl. These are the posts I live for on Pelican.

I would love to develop welding skills and had originally planned to do so but I had to be realistic if I ever want my project to be finished so I took my chassis to TRE. The guy that does their welding is really excellent. I couldn't be happier. If I get a chance I'll shoot some pics and post them.

Keep up the good work.

[JohnJL]

Classic,
Where did you find POR in Oz? I've used it with great success in the US but am a new arrival and can't find it anywhere here....

thanks

[Classic]

John,

Here's there site in Oz

http://www.ppc.au.com/index.htm