SWB 911R...the beginning

[Grady Clay]

Brother Paul,

For years I have been advocating Porsche AG do this. What is the market for a current technology (galvanized) chassis as a replacement spare part to fit a ’73 and be able to up- and back-date from there? Perhaps 10,000 and much more. I suspect all could be pre-paid. I don't see any regalutory issues as it is a better part than original '73. A chassis should be just like any other spare part.

I think the only isue is keeping track of VIN numbers - easily solved.

Porsche is dropping the ball and missing a profit opportunity.

Best,
Grady

[Macroni]

Originally Posted by Grady Clay

Porsche is dropping the ball and missing a profit opportunity.

Grady: They haven't missed a profit opportunity for awhile now.

Speedo: Still interested in Tombob's steering wheel?

[berettafan]

they'll probably get around to it when they are finished counting their profits from t-shirt sales.

gonna be a while though....

[Brother]

The only thing that I can think of is that new bodies would devalue existing cars. Only original cars with some sort of history would garner a premium. I think everything else would be worth the sum of its parts. It would be awesome though.

[aturboman]

New bodies have been available for some British cars (MGB etc) for over 20 years now.

More recently GM and Ford have licensed Camaro and Mustang repro bodies. Both are manufactured in Taiwan to a very high standard.

We discussed doing the 911 shell at SEMA this year and it is very feasible. Most of the tooling for the parts already exists and we know a factory that can product the finished shells (same as mentioned above).

The only issue left unresolved is licensing and Porsche would not allow it in a million years.

We figured a price point of around $10-12K would make a small proft if we could sell 50 shells per year.

Maybe someone at Porsche is listening??

[Brother]

So help me god if I ever bought a Porsche shell made in Taiwan.

[Crachian]

I think the big difference is that those cars that are reproduced are body on frame.

[gestalt1]

Originally Posted by Crachian

I think the big difference is that those cars that are reproduced are body on frame.

with good alignment jigs i would think spot welding the sheetmetal together would be exactly the same as porsche (or outside vendor) did when they ware originally making the shells. not to mention with the greater number of spot welds, compact dimensions and shorter wheelbase the strength of the shell is greater than a mustang or camaro of the same era even with the separate sub frames of those cars.

the other problem with making replacement tubs would be registering it, unless you are actually replacing an existing car's tub. otherwise it has no vin #, there must be a way around that.

[RWebb]

"made in Taiwan."

- Not likely that it would be made in such an upscale area. More likely to be made on the mainland. Or by the time this really happens, the Chinese may be outsourcing all their manufacturing to Zimbabwe...

[speedo]

I am thankful that I still have enough gas and wire to weld. It got cold here....

Time to finish up the front suspension pan topside. The gas tank support has been fitted as have the reinforcements for the A-arm suspension bolts. I welded in the reinforcements and primed. Never to be seen again.

The inside of the gas tank support got primed and positioned
I was able to use my spot welder for the center section, and used the MIG for the wings. The welds are nice enough that they didn't need to be ground down.

I prepped the fresh steel and pulled out the venerable POR 15.


The front pan is done. The remaining welding (on the front end of the car) is the drip strip that holds the rubber that seals the hood on the front bulkhead. The rotisserie front mount is in the way. Can't get to it till the car gets dropped.

Tomorrow I attack the perforated rear shelf. I still haven't decided if this is going to get patched from the top, or underside. Then it is on to closing up the quarter panels/rocker mating area. That will represent the conclusion of the rust repair. Then the welding of the oil cooler brackets, and the 72 oil tank supports. I'm still in the market for the complete 72 oil tank and accessories guys...so if you are one of those who has yet to get me pictures of the tanks you have for sale...this is your chance. Can anyone give me some rough estimates for positioning the filler on the right rear quarter...inches down from the window, and back from the door post?

[rvanderpyl]

How about 911R?




From Pic's previously posted here

[Crachian]

Good progress. What are you going to use for the drip strip?

[rennch]

Lars...will you let me know when you're doing the fab for the rocker panel/QP mating area? I'd like to be there to check it out, as I have to do the same thing.

Thanks bro..it's looking great.

I was going to make a suggestion that you fit a gas tank in there before you do the support, as a small deviation can make it so you can't fit the tank in, but you've probably already worked that out.

[Gmundboy]

Sub'd

[speedo]

The rear shelf was perforated aft of the seam. Water penetrated the rear shelf most likely through the rear window seal , and settled in the fibrous insulation. The shelf itself still had plenty of structural integrity, but even though the rust was removed during the sandblasting, I couldn't paint and cover it back up. It provides little rigidity to the chassis...but I wanted to remove the weakened steel and weld in a replacement piece.
Here is what I started with....from underneathfrom on top

Time to remove the bad metal and the upholstery backets as I won't be needing them for my spartan carpet replacement interior
Looks nasty, but the rest of the the shelf is sound

Now I need to fabricate the patch

[Jim Williams]

Also subscribed. Enjoying the welding tutorials, and don't want to miss out on further progress.

[speedo]

The removed bad metal had "flutes" which provided a bit of rigidty. I contemplated making a jig to create the flutes, but after further examination, I realized that the separation on the flutes varied...this is getting more compicated than I wanted. Furthermore, the mounts for the rear decklid hinges protruded up slightly on both sides and will require some custom fabrication to match. Heres what I started with
Time to start the "cut and fit"
Remove it, tweak it and reinstall
The "humps" on each end for the hinges determined the correct positioning
I'm getting closer...weld through primer applied on all surfaces prior to tack welding in the ends

[speedo]

The patch was clamped and tacked in place. Working from the middle to the outside I tacked and moved the clamps and repeated untill I was tacked all the way across
I need to now run a bead all the way around and the grind down the high spots.

Most of the tabs to mount the rear shelf upholstery have been gound off and appear as "bright spots in the pics".I need to keep reminding myself that this will all be hidden underneath a thin layer of sound insulation, and carpet.
POR 15 to protect it for the next 30 years...
I went ahead and sealed in the entire rear shelf...after all it is cleaned down to bare steel
From underneath...
No more perforations. The next time it flips back upsidedown to do the final spot weld grind on the underside of the floor and front suspension pan, I will use 3M seam caulk to close up the under side of the shelf.
I am now more or less done with all structural welding (although this wasn't really structural). I close up the quarter panels to the rockers and then I'm down to cosmetic welding...and more enjoyable "creative fabrication" . I am burnt on the major rehab stuff. Fiberglass arrives in a couple days. ..so I can start to fit. I also need to think about how the oil filler orifice is going to be designed in the right rear quarter. If anyone has a picture of the inside of the right rear wheel looking up towards the oil tank and inner fender wall....to see the orientation of the hoses, I would appreciate some help. I have a pretty good idea about orientation, but would like some concrete proof.

[John S]

great thread!

subscribed.

[Macroni]

Speedo,
You are ready for a TV show on Spike TV or the speed channel!
Weld my Ride! Actually, you did weld my ride
Luke