Carrera Outlaw Build

[getto822000]

Hi there,

I'm new here and recently bought my first Porsche 911. I've built several cars in the past (a few high hp Mitsubishi's 500-700hp race cars) and some classic American cars (1963 Impala SS, 1971 Olds Cutlass 442, 1974 Jeep CJ5). After getting the 911 bug, I set out to find a solid project to work from.

I bought a well used 1988 Carrera. Many miles, everything worn, needed paint and some rust repair, had been hit in the front at some point, many things broken, smokey oil leaks, you name it. But good bones and all original. Basically a base model 3.2, G50 coupe with almost no options, and oh yeah, in India Red. So rare....

The best news here is that the engine and transmission are sound. Leakdown testing showed only about 2-3% across any given cylinder. And the G50 synchros work well for extreme downshifts, etc. Much better than a rebuilt Mitsu in fact!

Anyway, I've taken it down to the frame, and am building it back up exactly the way I would have ordered it in 1973. Basically a touring trim RS, but with no radio, backdated heat, updated electronic AC system, sunroof delete, and basic interior. The goal is to have simplicity, but craftmanship and QUALITY. I'm using all steel, almost 100% new Porsche parts, and doing all the work myself. I'm learning a lot as I go, and probably will need to ask you all for advice!

Here is a shot of the car when I got it. It looks good in the photo but you can't see the wavy repaint that was done at some point, and the well disguised front end damage and rust on the quarter panels.


At first I thought that I'd refresh the interior, patch the rust, and slap on some EB Motorsports bumpers. So, I'd go chrome over faded, poorly repainted black trim. Here's what it looked like after that (but without a repaint yet).




I probably should have stopped there, but then I got the bug to go deeper, and build the car that I really wanted, all steel with vintage looks. The fiberglass was okay, but I wanted something a bit more durable. And after evaluating a few routes, I decided to go for it and do all the work myself. Next step, take it to the frame for a full inspection and build list.


The frame is in really good shape actually. I am now going spot by spot, fixing and rebuilding the metal work to be exactly what I want. First step, replace the roof with a non-sunroof skin. This involved making a custom tool to unpeel the crimped edge.



And then welding it up to shave the drip rails. First side is complete. Damn, this is a ton of work and lots of time on the TIG welder.



First side completed and epoxy primed. Next step will be to do the other side, but I'm taking a break and working on the front latch panel. Fenders, hood, bumper and latch panel arrived from Germany. Initial fitment. Not too bad on the gaps!



Next goes the latch panel. What a PITA to do. Removed old one, cleaned up area, fixed accident damage from previous owner who just undercoated over really picked over metal. Straightened that all out, and even located 1973 bumper brackets from Restoration Designs and put those on there.



Now epoxy primed the latch panel, and am in the process of repairing the undercoating. First with seam sealer (using DarrylD's technique), and next that whole area will get coated with high build rubberized underseal. Eventually it will all get painted body color.




Stay tuned for more details as this build develops. It could take awhile to complete this one!

[getto822000]

Quick update here. While waiting for the high-build underseal to arrive so I can finish the latch panel, I went ahead and started shaving the mirror holes. Made round discs from sheetmetal stock and used the TIG to put them in. They will require a tad of body filler to smooth out completely, but I'm pretty happy with it.

[Harpo]

Looking good

[pampadori]

Looks like a fun way to spend social distancing days! Not sure what you have planned for the mirrors but I bet you'll want to have better visibility than what most aftermarket mirrors offer.
They look cool but you can't actually see dickley-do.

[AG81]

Welcome...I'm following along at your pace......

[carwash]

Following along, looks awesome so far!

[getto822000]

Quick update here. I got the underseal in today finally and had just enough time to apply it. I'm using Darryl D's method of seam sealer to provide base texture similar to the factory PVC undercoating, and then using high build aerosol can paintable underseal to coat over it. It looks very heavy, thick, etc. Perhaps even a big heavier than the factory latch panel on the 1988. However, the chassis does have some areas that are as thick as this layer of undercoating. I'm pleased with the results overall. You can see where I blended the factory undercoating in with my custom undercoating. Once it is painted with a top coat, it will be difficult to see the transition areas near the holes.

This latch panel project ended up being pretty fun. And a great way to escape COVID for as long as it takes to get a vaccine.

Anyway, happy with the results, and looking forward to getting the fenders and bumper back on there and continuing on with the body work. Next will either be the second roof shave seam, or I might take a longer hiatus from that and move to rear RS steel bumper fitment. I'll have to trim the rear frame and adapt it to a 1973 style bolt on bumper parts. Overall goal here is to make this car to "factory or better" - level quality while adapting the 1988 tub to fit the 1973 parts.

[getto822000]

Originally Posted by pampadori

Looks like a fun way to spend social distancing days! Not sure what you have planned for the mirrors but I bet you'll want to have better visibility than what most aftermarket mirrors offer.
They look cool but you can't actually see dickley-do.

I bought one of these small chrome flag mirrors like the car in this photo. Leaning toward keeping the car India Red but with all chrome accents.... I know India Red. But it looks good most of the time!

[Jonny042]

Your path is similar to mine. We are practically neighbors!

Following along. Keep up the great work.

[Brookieslayer]

Looking forward to more updates. Nice work!

[super9064]

Great work, and I think India red is well suited to your build.

[Larmo63]

I love to watch these garage builds!!!

Nice work.

[Pedro '84 Coupe]

Good stuff!

[getto822000]

Thanks everyone for the kind words!

After letting the undercoating repair dry for a few days, I put the front clip back together and checked alignment, fitment, etc. Looks good enough for me.





I also spent some time adjusting the front bumper/fender brackets that I made that adapt the longhood fenders to the impact bumper tub. They are made from 2" steel angle iron that is 1/8" thick. I sourced the aluminum spacers from McMaster and the zinc plated bolts from Bel Metric. It looks pretty good. Now that the brackets work, I'll take them back off, prime, paint and undercoat them to match the tub and soon the inner fenders and bumper too.





Now I rotated the dolly around so I can get going on the rear bumper fitment. That seems like a more fun project than finishing the other side of the roof (whole day of welding and grinding...). Once the rear bumper is looking as good as the front, I'll then either move to rear quarter rust repairs on each side, or the other roof weld... Hoping to get all this metalwork done and then any body filler by the end of the year. Still not sure about paint. I don't really have a good setup for that. Anyone know a paint shop that could flat this car and paint it for me after I finish the body work? I live about one hour south of Minneapolis.

[gomezoneill]

Nice project. I have to say that's one of the dirtiest garage's I've ever seen.

[getto822000]

Originally Posted by Jonny042

Your path is similar to mine. We are practically neighbors!

Following along. Keep up the great work.

Jonny, just came across your build thread. Awesome work!

I'm interested in doing my own paintwork too, but my garage is attached to my house so I'm worried about fumes. Not sure what to think of it. Maybe send the wife and kids off for a week or something?

Or if I can do all the metalwork, customization, filler work, etc and then have a paint shop flat, paint and polish it for me.. that could work. There are some options in the metro area, but many of them seem super busy with projects right now, mostly older American hot rods.

[carwash]

My fear also is the body shop keeping my car hostage for 3 years.

[getto822000]

Originally Posted by carwash

My fear also is the body shop keeping my car hostage for 3 years.

Yeah that would be a pain. I could handle maybe 6 months and be okay. I still have the all the other parts (engine, trans, etc) to refresh and it would be nice to have space to spread out and do that while the shell is getting done.

[carwash]

I’m not too far from paint, or so I keep telling myself. Just bumped my thread with KW pics if yer interested.

[chrisbalich]

Off to a great start!
Keep it up.