Attacking my first real project and it feels good.
 

Hi there fellow Pelicans. Been a while since I posted here, due to moving house dealing with Christmas and not having any internet connection from the new home yet! But I have not been idle in the garage either :)

I was trying to find a good way to store a history of this project somewhere, and decided that this forum was probably as god a place as any - now I know that this is not a major project in comparison to some of the people here, but for me, it is still scary whenever I think about what I have done so far and what is left to do - after all my day job is in an office, and has nothing to do with cars!!!

This all started with a simple task. Remove front bumper and replace with lighter glass fibber one. But when I removed the front bumper and washer bottle etc, I was faced with this
http://forums.pelicanparts.com/uploa...1168423911.jpg

That is when I decided that I first of all had to bite the bullet and start to understand how to do some metal work on my car, and secondly it was time to consider all the other big (whilst you are in there) projects - and here are some pictures of where I am today!!!
http://forums.pelicanparts.com/uploa...1168423983.jpg
http://forums.pelicanparts.com/uploa...1168424009.jpg
http://forums.pelicanparts.com/uploa...1168424082.jpg

More pictures...
 

http://forums.pelicanparts.com/uploa...1168424167.jpg

http://forums.pelicanparts.com/uploa...1168424194.jpg

http://forums.pelicanparts.com/uploa...1168424230.jpg

http://forums.pelicanparts.com/uploa...1168424256.jpg

I also discovered bad rust on the bottom of the petrol tank etc, so I will be starting a large WTB here soon :)

More progress to follow......

Holly Magnolia !!

You have been a busy boy, Pål! Great work!

Makes me wonder though, how the metal status of my car is. There is nothing on the exterior suggesting any major rust attack, but seeing as you found out by coincidence..... ouch.

Hope you all have settled in your new place and life in general is good! SmileWavy

Yes, I can recommend a good inspection Markus. I was convinced that I had a rust free car, but I have descended to Porsche hell, where the Devil puts rust in hidden corners and under the rubber stuff they used under our cars in the factory....

Or maybe my best advise would be. Just drive the car, have fun - and do nothing else. Ignorance is better than the sick feeling you get when you find the front bumper is held in place by rust and nothing else http://www.pelicanparts.com/support/smileys/puke.gif

I think I will stick with ignorance for now. There is no place for a project similar to yours in my life for the moment.

What kind of equipment have you used to get rid of the rust ?

That has been one good part of this project, getting new tools and experience on using them :D

For the rust removal I have used an angle grinder and a wire brush wheel attached to a drill. I also decided to do the larger project of removing all the undercoating in the arches and under the car at the same time - man what a job :rolleyes: I tried everything I could think about from paint stripper to heat, and in the end I found good old fashioned hard work and a scrapper to work the best. I have now managed to clear both front arches and the bottom of the car about 1/4 way down to the back :eek:
I will then treat with the Por stuff (cleaner and rust stuff - metal ready), paint with silver then black Por-15, and then finish with some nice red paint :D

And it is really fun to learn to do metal work on my beloved 911. I am sure there are people who could do a much neater job, but at least I can say "I did this" :cool:

At least I will not be scared about what I will find when I focus on the rear suspension etc when I get back there for the following projects :D

Another picture - after cutting away the bad rust, and before cleaning the surface up for welding :)
http://forums.pelicanparts.com/uploa...1168433006.jpg

Impressive, to say the least!

Hey, maybe we could trade projects in the future. I do the valves and you do the rust ! :D

Sounds good to me :D

Well done Pål! Nothing like the fruits of your own labor!

Thank you Darryl. I have a long way to get to your standard :)

Good work there!

Great, we should all look down there sometimes :)

Update
 

Been working hard the last week or so. here is the update pictures on the replacement bumper shock support.
Back plate welded in and primed with zinc primer.
http://forums.pelicanparts.com/uploa...1172049277.jpg

New bumper shock welded in place.
http://forums.pelicanparts.com/uploa...1172049348.jpg

Cleaned and painted with first cote of Por15 (Silver)
http://forums.pelicanparts.com/uploa...1172049390.jpg

And then a cote of black Por15.
http://forums.pelicanparts.com/uploa...1172049442.jpg

And this was my first welding job :D

Here are some pictures of the other front end work. I striped the old rubber undercoating, did the usual Por rust treatment and painted with two cotes of Por15 (silver then black). Once I have done all the other project work I will cover the Por15 with Por15 Self Etching primer and then a layer of red :)

http://forums.pelicanparts.com/uploa...1172049697.jpg

http://forums.pelicanparts.com/uploa...1172049732.jpg

Holly canolly! That is impressive work, Pål.

Little missus started to complain yet? :D

That is why it is taking some time - make sure I spend some time with her as well ;)

Nice job! Glad to hear you are using POR 15. It is the best.

I guess I'm next
 

I posted this awhile back, but have been living in fear ever since.

As far as the rest of you living in denial, you should probably check that area.

http://forums.pelicanparts.com/showthread.php?s=&threadid=280904&highlight=batter y+rust

I recently also removed another pound or so of road grime/gravel from above the A/C hoses in that same wheel well, but there are no signs of rust, at least inside my boot/trunk.

Kroggers, you may want to look up there also if you haven't done so, but I'm guessing you have. I thought for sure the driver's side wing/fender would need to be removed to do this job, but apparently not. That's comforting.

Keep us posted on your progress.

Time for an update
 

Some new pics of the project :)
http://forums.pelicanparts.com/uploa...1176056661.jpg

http://forums.pelicanparts.com/uploa...1176056720.jpg

http://forums.pelicanparts.com/uploa...1176056753.jpg

http://forums.pelicanparts.com/uploa...1176056789.jpg