Here we go again! Zuffenhaus MS RSR project...

[eimkeith]

well, that was my first time in 43 years; but if it happens again, I'll certainly do that!

BTW, I love the waterfront there; coming out of the tunnel onto the bridge was like a miracle, I really enjoyed it. So industrial/gothic - there has to be some Southern undercurrent in the design there, very cool.

[eimkeith]

So I started working on a P852 windshield template this morning. I'm having trouble getting good references to the construction of the original tool, so I started with square tubing... May need to use solid bar instead.

Here's the P852:





And here is my tube corner:







I'm thinking I could control the cross section through the tight bend better with solid bar...

I'll be using these to verify windshield orifice dimensions when installing the early dash top and roof.


keith.

(sent from my rotary dial phone.)

[Tom '74 911]

Originally Posted by eimkeith

So I started working on a P852 windshield template this morning.

Very interesting to see you tackle this... I just ordered some square tube on Friday to start this exact project... I think your finished templates are going to be far better than mine!

I have a few additional images of the templates which maybe you've seen already? Also, the Porsche factory restoration videos from when they restored the car they raffled off have some scenes where the templates are present...

My methods were going to be much more crude than yours... and I'm assuming that it'll take a lot of time & experimentation to get something that'll be worthwhile using in the end. Nice work on that first corner.

[eimkeith]

outstanding!

those photos are really great - and making those door opening templates is going to suck! (I'll save that for a later project.)

I'm in the market for these if any ever turn up for sale, btw.

[Tom '74 911]

Originally Posted by eimkeith

outstanding!

those photos are really great - and making those door opening templates is going to suck! (I'll save that for a later project.)

I'm in the market for these if any ever turn up for sale, btw.

I agree 100% on the sucking comment! & I'd buy a set if I came across them too! Maybe we could go halfsies? : )

[eimkeith]

you're on - I'll take the front windshield, left door and quarter window

[jjeffries]

How about making these in tow steps:
1. Form the basic piece out of round steel bar, easier to bend, with 1/8" clearance around each edge, then
2. Add 1/8" thick angle stock to fit around the outside and to create the actual edge; could be done in pieces, notched to make create corners.
Not the world's greatest description of an idea, hope you get the gist.
I've always thought these factory tools were the coolest thing, totally characteristic of Porsche philosophy. John.

[eimkeith]

Originally Posted by jjeffries

How about making these in tow steps:
1. Form the basic piece out of round steel bar, easier to bend, with 1/8" clearance around each edge, then
2. Add 1/8" thick angle stock to fit around the outside and to create the actual edge; could be done in pieces, notched to make create corners.
Not the world's greatest description of an idea, hope you get the gist.
I've always thought these factory tools were the coolest thing, totally characteristic of Porsche philosophy. John.

not sure if that would account for the plane changes at the windshield edges and pinch weld flange; although I'd considered making it out of 2 runs of 3/4 angle to ease the construction (but double the work...)

It would be helpful to know if the factory tools are hollow or solid at the perimeter.

[eimkeith]

Ok, the bar seems to be the way to go (although more time consuming to heat & bend...)






keith.

(sent from my rotary dial phone.)

[rennch]

Pardon my ignorance on this, but what does the square bar serve to do? What are you creating with this?


Sent from my iPad using Tapatalk

[eimkeith]

The green windshield template jig shown in post #443.

I've removed the dash from this car to replace it with an early dash core, which could possibly affect my cowl position (and consequently the windshield opening) when it is welded back in. I want to make certain the windshield seal won't leak, by making sure my windshield opening doesn't change. This template is just for that: verification of windshield opening dimensions for use when replacing the roof, cowl, or other major repair/panel replacement.

I ran out of oxygen on the torches, just shy of finalizing the corner piece:



Not the best thing I've ever bent, but not too shabby.


keith.

(sent from my rotary dial phone.)

[cnielsen]

These would be handy jigs as well...since the factory replacement quarters fit like a sock on a rooster!



More pics of the factory units

[eimkeith]

Yeah, I'll be doing those also, in addition to the rear windshield and the doors.


keith.

(sent from my rotary dial phone.)

[eimkeith]

Back at it.






keith.

(sent from my rotary dial phone.)

[jjeffries]

Highly impressive. Some serious forces involved there, mechanical and temperature. John.

[eimkeith]

Thanks! this stuff takes me back to college:



(I was doing stuff like this then)





OK, so I ran out of gas on the torches about the time the oil cooler modifications were done.



Remember the end-tank revisions necessary for correct through-trunk lines and bumper clearance?





well, the revision worked out just fine:






Back on the windshield template tool tomorrow.

[eimkeith]

Made strides on the windshield template tool today.





I got overzealous and finish welded my A pillar joint from the outside before tacking the inside of the joint and it drew on me a little (was pretty tight to the chassis beforehand) - not bad, but I'm hoping I can pull it back when I weld up the inside joint.

Aside from that, I have the passenger upper corner to touch up and cut in, and then I can finish the perimeter.

Then 2 more braces and I can get back on the Mary Stuart dash!



keith.

(sent from my rotary dial phone.)

[eimkeith]

Ok, so the draw while welding was a setback. I had to cut it apart and make new vertical braces, clamp it up and do it over. Just now trimming in the passenger top corner.


keith.

(sent from my rotary dial phone.)

[eimkeith]

All tacked up; one brace to go!




keith.

(sent from my rotary dial phone.)

[Tim K]

Just so I understand, the later upper-dash sheet metal is different enough that it cannot accommodate the early dash? And you're drilling out the spot welds along the bottom of the window opening to R&R with the new one?

Also, are you removing the entire roof skin including the 'cowl', or just a panel to delete the sunroof?

Just trying to understand the concern over structural support.

Thanks for sharing your progress,

Tim K